WO2019191430A1

WO2019191430A1 - Rollers with inserts for gripping tubular members

Info

Publication number: WO2019191430A1
Application number: PCT/US2019/024585
Authority: WO
Inventors: Adrian Marica
Original assignee: National Oilwell Varco, L.P.
Priority date: 2018-03-28
Filing date: 2019-03-28
Publication date: 2019-10-03

Abstract

An iron roughneck is configured to make and break threaded connections between a pair of tubular members. An example of an iron roughneck includes a torque wrench to grip a first tubular member and a spin wrench to engage and rotate a second tubular member. The spin wrench includes a wrench frame, a roller supported by the wrench frame, and a motor configured to rotate the roller. The roller includes a cylindrical roller body with a cylindrical outer surface, a plurality of retention pockets in the roller body with pocket openings in the outer surface of the roller body, and a plurality of inserts, each insert disposed in one of the retention pockets, wherein each insert is moveable relative to the roller body.

Description

ROLLERS WITH INSERTS FOR GRIPPING TUBULAR MEMBERS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims benefit of U.S. provisional application No. 62/649,532 filed March 28, 2018, and entitled“Rollers with Inserts for Gripping Tubular Members,” and U.S. provisional application No. 62/684,987 filed June 14, 2018, and entitled“Rollers with Inserts for Gripping Tubular Members,” both of which are incorporated herein by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

BACKGROUND

[0003] This disclosure relates generally to coupling and decoupling threaded tubular members. More particularly, it relates to an apparatus and a system to rotate a tubular member while making or breaking a threaded connection.

[0004] Oil well operations often require the assembly and, alternately, the disassembly of “strings” formed from multiple tubular members threadingly joined end-to-end. The tubular members may include pipe segments or downhole tools. An iron roughneck is a tool that is commonly used to both to thread together or“make” a string of tubular members and also to unthread or“break” a connection between tubular members. A typical iron roughneck includes a pair of powered torque wrenches or“tongs” aligned with a spin wrench. A spin wrench includes a pair of clamping jaws powered by a hydraulic piston-cylinder assembly, and the jaws include multiple rollers to grasp and transfer rotation to a tubular member. Current iron roughnecks use rollers with either smooth or textured surfaces. Each roller is turned by a hydraulic motor, and friction is employed to grasp and turn the pipe.

[0005] While making a connection, the spin wrench rotates one tubular member relative to another to engage a major portion of the threads. Then, the torque wrenches are used to tighten the connection.

[0006] During operation, roller rotation is initiated before the spin wrench grasps the tubular member positioned within its jaws. The use of rollers with textured surfaces helps to engage the moving rollers and the pipe but contributes to disturbing the surface of the pipe, e.g., scoring or creating“teeth” marks, and to sparking. In order to avoid sparks, water is sometimes sprayed before and during the contact between the moving rollers and the pipe. However, this decreases the coefficient of friction between pipe and rollers. In turn, the reduced friction causes slippage between the rollers and the tubular member. In order to decrease slippage, the rollers are pushed or clamped with a greater force against the pipe. This increased force is achieved by applying greater hydraulic pressure to the clamping jaws.

BRIEF SUMMARY OF THE DISCLOSURE

[0007] These and other needs in the art are addressed in one embodiment by an iron roughneck configured to make and break threaded connections between a pair of tubular members. The iron roughneck includes a torque wrench to grip a first tubular member and a spin wrench to engage and rotate a second tubular member. The spin wrench includes a wrench frame, a roller supported by the wrench frame, and a motor configured to rotate the roller. The roller includes a cylindrical roller body with a cylindrical outer surface, a plurality of retention pockets in the roller body with pocket openings in the outer surface of the roller body, and a plurality of inserts, each insert disposed in one of the retention pockets, wherein each insert is moveable relative to the roller body.

[0008] In another embodiment, a spin wrench to engage and rotate a tubular member includes, an operational axis, along which the tubular member is to be received, a frame disposed about the operational axis, and a first roller. The first roller includes a first longitudinal axis parallel to and spaced apart from the operational axis. The first roller is supported by the frame. In addition, the spin wrench includes a second roller with a second longitudinal axis parallel to and spaced apart from the operational axis and the first roller longitudinal axis. The second roller is also supported by the frame. Still further, the spin wrench includes a motor configured to rotate the rollers multiple revolutions in either of two opposite directions. Each roller includes a cylindrical roller body with a convex outer surface disposed about the corresponding roller longitudinal axis, a plurality of retention pockets in the roller body with pocket openings in the outer surface of the roller body; and a plurality of inserts, wherein each insert is disposed in one of the retention pockets, and wherein each insert includes a convex outer surface. An exposed portion of the outer surface of each insert is located beyond the outer surface of the roller body. The second roller and second longitudinal axis are transversely movable with respect to the first roller and the first longitudinal axis to engage and rotate the tubular member. 02

[0009] In another embodiment, a method for making and breaking threaded connections between a pair of tubular members with an iron roughneck. The method includes gripping a first tubular with a torque wrench of an iron roughneck. In addition, the method includes rotating a roller of a spin wrench using a motor. Further, the method includes engaging a second tubular member with the roller. Still further, the method includes causing a roller body of the roller and a plurality of inserts held by the roller body to engage alternately the second tubular member to cause the second tubular member to rotate more than one revolution in either of a first or a second direction.

[0010] Thus, embodiments described herein include a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The various features and characteristics described above, as well as others, will be readily apparent to those of ordinary skill in the art upon reading the following detailed description, and by referring to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a detailed description of the disclosed exemplary embodiments, reference will now be made to the accompanying drawings, wherein:

[0012] Figure 1 shows an elevation view of an iron roughneck having a spin wrench with spin wrench rollers having cylindrical inserts in accordance with principles described herein;

[0013] Figure 2 shows a perspective top view of the spin wrench of Figure 1;

[0014] Figure 3 shows a perspective bottom view of a wrench roller in the spin wrench of

Figure 2;

[0015] Figure 4 shows a top view of the wrench roller of Figure 3 without any inserts installed;

[0016] Figure 5 shows a top view of the wrench roller of Figure 3 with inserts installed;

[0017] Figure 6 shows an example of the operational use of the spin wrench of Figure 2, with the wrench roller in an unengaged or released position;

[0018] Figure 7 shows part of a sequence in the operational use of the spin wrench of Figure 2, with the wrench roller in an engaged or gripping position;

[0019] Figure 8, in accordance with principles described herein, shows another embodiment of a spin wrench with a wrench roller in an engaged or gripping position as part of a sequence of the operational use of the spin wrench; 02

[0020] Figure 9 shows a further engaged or gripping position of the wrench roller of Figure 8 in the sequence of the operational use of the spin wrench;

[0021] Figure 10 shows still another engaged or gripping position of the wrench roller of Figures 8 and 9 in the sequence of the operational use of the spin wrench;

[0022] Figure 11 shows an additional engaged or gripping position of the wrench roller of Figures 8-10 in the sequence of the operational use of the spin wrench; and

[0023] Figure 12 shows a method for making and breaking threaded connections between a pair of tubular members, in accordance with principles described herein.

NOTATION AND NOMENCLATURE

[0024] The following description is exemplary of certain embodiments of the disclosure. One of ordinary skill in the art will understand that the following description has broad application, and the discussion of any embodiment is meant to be exemplary of that embodiment, and is not intended to suggest in any way that the scope of the disclosure, including the claims, is limited to that embodiment.

[0025] The figures are not drawn to scale. Certain features and components disclosed herein may be shown exaggerated in scale or in somewhat schematic form, and some details of conventional elements may not be shown in the interest of clarity and conciseness. In some of the figures, in order to improve clarity and conciseness, one or more components or aspects of a component may be omitted or may not have reference numerals identifying the features or components. In addition, within the specification, including the drawings, like or identical reference numerals may be used to identify common or similar elements.

[0026] As used herein, including in the claims, the terms“including” and“comprising,” as well as derivations of these, are used in an open-ended fashion, and thus are to be interpreted to mean“including, but not limited to... ” Also, the term“couple” or“couples” means either an indirect or direct connection. Thus, if a first component couples or is coupled to a second component, the connection between the components may be through a direct engagement of the two components, or through an indirect connection that is accomplished via other intermediate components, devices and/or connections. The recitation“based on” means“based at least in part on.” Therefore, if X is based on Y, then X may be based on Y and on any number of other factors. The word“or” is used in an inclusive manner. For example,“A or B” means any of the following:“A” alone,“B” alone, or both“A” and“B.” 02

In addition, the word“substantially” or“generally” means within a range of plus or minus 10%.

[0027] In addition, the terms“axial” and“axially” generally mean along or parallel to a given axis, while the terms“radial” and“radially” generally mean perpendicular to the axis. For instance, an axial distance refers to a distance measured along or parallel to a given axis, and a radial distance means a distance measured perpendicular to the axis. Furthermore, any reference to a relative direction or relative position is made for purpose of clarity, with examples including “top,” “bottom,” “up,” “upper,” “upward,” “down,” “lower,” “clockwise,”“left,”“leftward,”“right,” and“right-hand.” For example, a relative direction or a relative position of an object or feature may pertain to the orientation as shown in a figure or as described. If the object or feature were viewed from another orientation or were implemented in another orientation, it may then be helpful to describe the direction or position using an alternate term.

[0028] The plural term“threads” broadly refer to a single, helical thread path, to multiple, parallel helical thread paths, or to portions of one or more thread paths, such as multiple crests axially spaced-apart by multiple troughs.

[0029] The use of ordinal numbers (i.e., first, second, third, etc.) to identify one or more components within a possible group of multiple similar components is done for convenience and clarity. Ordinal numbers that may be used outside the claims for members of a particular group of components may not necessarily correspond to the ordinal numbers used within the claims when referring to various members of the same group or a similar group of components.

DETAILED DESCRIPTION OF THE DISCLOSED EXEMPLARY EMBODIMENTS

[0030] Referring to Figure 1, in an exemplary embodiment, an iron roughneck 100 includes a spin wrench 110 and a torque wrench 120 mounted to a movable end of an articulating arm assembly 130. Arm assembly 130 is pivotably coupled at a mounting column 135. Mounting column 135 extends vertically from an operational floor 136 along a mounting axis 138. Operational floor 136 may be the floor of a drilling rig, for example. Spin wrench 110 and torque wrench 120 are aligned along an operational axis 141. Wrenches 110, 120 and their axis 141 may be pivoted about axis 138, may be moved radially toward and away from axis 138 in the horizontal plane, and may be moved vertically by the action of arm assembly 130. During operations, axis 141 may be held vertically or may be adjusted to another orientation. 02

Movement of wrenches 110, 120 may be achieved to align axis 141 with a pair of tubular members, such as pipes 142, 144, which are to be either threaded together to“make” a “string” of tubular members or unthreaded from each other to“break” a string of tubular members with wrenches 110, 120.

[0031] Spin wrench 110 includes a plurality of spin wrench rollers 112 held in a wrench frame 114 and configured for rotation by a motor 116. Torque wrench 120 includes a lower tong 122 to grip the lower tubular member, e.g., pipe 142, and an upper tong 124 to grip, rotate, and tighten or torque the upper tubular member, e.g., pipe 144.

[0032] Figure 2 shows structure of spin wrench 110, including a plurality of rollers 112 held in wrench frame 114, wherein the position of the rollers 112 relative to operational axis 141 or the pipe 144 may be changed or adjusted by actuation of a hydraulic piston-cylinder assembly 148. Wrench frame 114 includes a back plate or backbone member 150 extending horizontally from a left end 152 to a right end 153, and includes a first and a second arm assembly or jaw 160 that oppose each other. Each jaw 160 is coupled pivotally to member 150 at an end 152, 153 by a vertical pivot joint 158. In Figure 2, each jaw holds a pair of rollers 112, and member 150 and joints 158 are located between rollers 112 and piston- cylinder assembly 148.

[0033] Each jaw 160 includes an upper and a lower arm 161 extending horizontally from an arm first end 162 to an arm second end 163. Each jaw 160 also includes an upper and a lower swivel plate 166 pivotally mounted to the second ends 163 of both arms 161 by a pivot axle 168. Hydraulic piston-cylinder assembly 148 is coupled to each jaw 160 through a pivot joint 178 at the first ends 162 of arms 161. Each pivot joint 158 of member 150 extends through a pair of arms 161 at a location between arm ends 162, 163. Assembled as described, backbone member 150 and the two opposing jaws 160 of wrench frame 114 form an adjustable jaw opening 180 located between the two opposing pairs of upper and a lower swivel plates 166 and extending toward member 150. Jaw opening 180 is disposed around operational axis 141 and includes a perimeter 182 formed in part by edges or sides of swivel plates 166. Opening 180 is configured to receive a tubular member, such as pipe 144, that is to be rotated by wrench 110.

[0034] Referring now to Figure 2 and Figure 3, each spin wrench roller 112 includes a cylindrical body 210 extending along a central, longitudinal axis 211, a concentric axle 212, and a plurality of inserts 215 positioned within and extending radially from roller body 210. Roller central axis 211 is parallel to operational axis 141. For each roller 112, portions of 02 body 210 and one or more inserts 215 extend radially through the internal perimeter 182 of frame 114 into the jaw opening 180. Axle 212 extends beyond each end 222, 223 of body 210 and is rotationally coupled to a pair of upper and lower swivel plates 166. Axle 212 and therefore roller 112 are configured to be rotated about axis 211 by motor 116, which was introduced in Figure 1.

[0035] Referring to Figure 3 and Figure 4, cylindrical body 210 of roller 112 extends from a first end 222 to a second end 223 along axis 211. Body 210 includes a roller body outer surface 226 that is convex or generally cylindrical and centered on axis 211 and includes a plurality of grooves or retention pockets 230. Each pocket 230 extends longitudinally through ends 222, 223 parallel to axis 211 and extends radially to or through outer surface 226, forming a rectangular pocket opening 232 that extends parallel to axis 211 along the length of body 210. Pockets 230 are circumferentially spaced about roller body 210 along a circular or cylindrical region 233 located inward from outer surface 226. The example of Figure 4 includes twelve pockets 230 that are evenly spaced. Each pocket 230 is spaced apart from its neighbor by an angle 234 of 30 degrees. In various embodiments, the number of pockets 230 is more or less than twelve and the angle 234 is more or less than 30 degrees. Pocket 230 includes a convex or generally cylindrical inner surface 236 that is bounded in part by opening 232. Full-diameter portions 235 of body 210 are located between each adjacent pair of pockets 230 and their openings 232. The roller body outer surface 226 is disposed on the plurality of full-diameter portions 235. Thus, outer surface 226 is circumferentially segmented about axis 211 and may be described as a discontinuous cylindrical surface divided into a plurality of surface regions 227, due to pocket openings 232. Outer surface 226 and its surface regions 227 are uniform, having a uniform diameter with respect to roller axis 211. In one aspect, outer surface 226 can be said to be part of a full circumference“envelope” that also spans openings 232 to replicate a full circumference of the cylindrical body 210. In some embodiments, a uniform surface lacks features that are configured to bite into a tubular member engaged by the surface, features such as a knurled pattern, multiple narrow grooves, or indentations having a herringbone pattern, as examples. Such grooves or indentations in a non-uniform surface could and sometimes do cause plastic deformation, leaving marks as a result of biting into a tubular member. In some embodiments, a uniform surface includes granularity, e.g., like sandpaper that is rougher than 440 grit. In some embodiments, a uniform surface is smooth, e.g., smoother than 440 grit sandpaper. 02

[0036] Continuing to reference Figure 3, roller body 210 contains twelve inserts 215, one in each pocket 230. Each insert 215 includes a body 240 extending along a central, longitudinal axis 241 and a convex outer surface 242. Each insert 215 is positioned within one of the pockets 230 so that axis 241 is parallel to roller axis 211. A majority of insert body 240 is disposed within a pocket 230. A minor portion of insert body 240 and at least a portion of outer surface 242 extend radially beyond the opening 232 and beyond outer surface 226 of roller body 210. In this example, pockets 230, insert bodies 240, and surfaces 236, 242 are each cylindrical and uniform. In some embodiments, each surface has a uniform diameter. In some embodiments, each surface lacks features that are configured to bite into a tubular member engaged by the surface, features such as a knurled pattern, multiple narrow grooves, or indentations having a herringbone pattern, as examples. Insert axis 241 is centrally located in body 240. Inserts 215 are moveable relative to the cylindrical body 210 of roller 112, being configured to be rotatable within a pocket 230. Thus, inserts 215 are multiple rollers held within a larger roller body 210. Inserts 215 are held axially within body 210 by a pair of annular retaining rings 238 (one is visible in Figure 3) that are circumferentially disposed around axle 212 adjacent the ends 222, 223 of body 210.

[0037] Referring now to Figure 5, insert body 240 is characterized by an insert width 244 extending perpendicular or tangential to the longitudinal axis 211 of cylindrical body 210. In this example, the width 244 of body 240 is a diameter. The portion of outer surface 242 that is located beyond (e.g., outside of the roller body 210 envelope) the outer surface 226 extends perpendicular or tangential to longitudinal axis 211 by a width 246. In some embodiments, this exposed portion of convex surface 242 is characterized by an exposed width 246 that is at least one eighth of the full width 244 of the insert but less than the width 244. In some embodiments, width 246 is at least one quarter of width 244. In Figure 5, width 246 is substantially equal to the width of opening 232.

[0038] Figure 6 and Figure 7 show an operational use of spin wrench 110. In the top view of Figure 6, a pipe 144 extends vertically and is located within opening 180. Configured according to the discussion above, a roller 112 along with an insert 215 extends through perimeter 182 into opening 180. Jaw 160, represented by a swivel plate 166, is moving toward pipe 144 as indicated by arrow 302, and roller 112 is rotating as indicated by arrow 304. Neither roller body 210 nor any of the inserts 215 have achieved contact with pipe 144, which is stationary. For at least this embodiment, inserts 215 move about axis 211 along with body 210 while remaining stationary relative to roller body 210. In this manner, spin wrench 02

110 and roller 112 are in an unengaged or released position relative to pipe 144. Referring now to Figure 7, jaw 160 with roller 112 has moved sufficiently to achieve contact with pipe 144. In this manner, spin wrench 110 and roller 112 are in an engaged or gripping position relative to pipe 144. In this scenario, an insert 215 is the first component to make contact with the pipe. Jaw 160, aided by hydraulic piston-cylinder assembly 148, applies a clamping force 306 against pipe 144, which applies a reaction force supported by the opposing jaw 160 (not shown in Figure 7). Force 306 allows insert 215 to transfer the torque of rotation 304 to pipe 144, causing it to begin rotating, as indicated by pipe rotation arrow 308. For some embodiments or some instances, torque transfer between roller body 210, insert 215, and pipe 144 may cause insert 215 to wedge or bind within pocket 230 and remain stationary with respect to roller body 210. However, in Figure 7, torque transfer among roller body 210, insert 215, and pipe 144 causes insert 215 to roll against pipe 144 and to rotate relative to body 210, at least initially, due to contact between pipe 144 and the exposed portion of convex surface 242 on insert 215. This rotation of insert 215 is indicated by arrow 310. As roller 112 continues to rotate according to arrow 304, the engaged insert 215 will move away from the pipe and a full-diameter portion 235 of body 210, i.e., outer surface 226, will come into contact with pipe 112, motivated by force 306. Although operational events have been described with respect to the one roller 112 shown in Figure 6 and Figure 7, it is to be understood that the operation of wrench 110 includes the interaction of multiple or all four motor-driven rollers 112 shown in Figure 2.

[0039] Figure 8 presents another embodiment of a spin wrench consistent with the present disclosure. Spin wrench 400 is similar in configuration and operation to spin wrench 110. For example, wrench 400 includes a motor-driven spin wrench roller 402 rotatably mounted to a swivel plate 406 of an arm assembly or jaw 405, which are members of a wrench frame 404. In at least some embodiments, jaw 405 includes another motor-driven spin wrench roller 402. Although not shown, wrench frame 404 includes a second jaw 405 with one or multiple motor-driven spin wrench rollers 402 that oppose roller 402 of jaw 405 in Figure 8. These opposing jaws are mounted to a backbone member and actuated by a hydraulic piston- cylinder assembly, similar to the arrangement of wrench 110. Variations are possible. Wrench 400 forms an adjustable jaw opening 180 located between the two opposing jaws. Jaw opening 180 is disposed around an operational axis 409 and includes a perimeter 182 formed in part by edges or sides of swivel plate 166. Like spin wrench 110, wrench 400 may 02 be used as a member of an iron roughneck such as roughneck 100 of Figure 1. In Figure 8, a pipe 144 is received in opening 180.

[0040] Similar to roller 112 described above, spin wrench roller 402 includes a cylindrical body 410 extending along a central, longitudinal axis 411, and a plurality of inserts 215 positioned within and extending radially from roller body 410. Roller central axis 411 is positioned parallel to operational axis 409. For each roller 402, portions of body 410 and one or more inserts 215 extend radially through the internal perimeter 182 of frame 404 into the jaw opening 180.

[0041] Cylindrical body 410 is similar to body 210 of roller 112. For example, cylindrical body 410 includes a roller body outer surface 426 that is convex or generally cylindrical and centered on axis 411, and body 410 includes a plurality of grooves or retention pockets 430. Each pocket 430 extends longitudinally in body 410 parallel to axis 411 and extends radially to or through the outer surface 426, forming a rectangular pocket opening 432 that extends parallel to axis 411 along the length of body 410. Pockets 430 are circumferentially spaced about roller body 410. In the example of Figure 8, body 410 includes nine pockets 430 evenly spaced by 40 degrees, as indicated by a spacing angle 434, though the number of pockets and spacing can be varied in other embodiments. Pocket 430 includes a convex or cylindrical inner surface 436 that is bounded in part by opening 432. An insert 215 is contained within each pocket 430. Full-diameter portions 435 of body 410 are located between each adjacent pair of pockets 430 and their openings 432. The roller body outer surface 426 is disposed on the plurality of full-diameter portions 435. Thus, outer surface 426 is circumferentially segmented about axis 211 and may be described as a discontinuous cylindrical surface divided into a plurality of surface regions, due to pocket openings 432 (wherein a continuous cylindrical surface is represented by a full circumference“envelope” spanning pocket openings 432 and the segments of surface 426). Outer surface 426 is uniform, having a uniform diameter with respect to roller axis 411, lacking features that would bite into the second tubular member, such as a knurled pattern or grooves in a herringbone pattern, as examples.

[0042] Continuing to reference Figure 8, inserts 215 are configured and positioned as described above, having a cylindrical body 240 extending along a longitudinal axis 241 and a convex outer surface 242. A portion of each body 240 and at least a portion of outer surface 242 extend radially beyond the opening 432 and beyond the outer surface 426, or envelope, of roller 402. In this example, pockets 430, insert bodies 240, and surfaces 436, 242 are 02 cylindrical and uniform, each surface having a uniform diameter, and the insert axis 241 is centrally located in body 240. Inserts 215 are moveable relative to the cylindrical body 410 of roller 402, being configured to be rotatable within a pocket 430. Thus, inserts 215 are multiple rollers held within a larger roller body 410. Insert body 240 is characterized by an insert width or diameter 244 extending perpendicular or tangential to the longitudinal axis 411 of cylindrical body 410. The portion of outer surface 242 that is located beyond, i.e., outside, the roller outer surface 426 extends perpendicular or tangential to longitudinal axis 411 by a width 446. This exposed width 446 of convex surface 242 is at least one eighth of the width 244 of the entire insert but less than width 244. In some embodiments, width 446 is at least one quarter of width 244. In Figure 8, convex surface width 446 is substantially equal to the width of opening 432.

[0043] In various examples, the operation of wrench 400 is initiated or achieved in the same manner as described for wrench 110 with respect to Figure 6 and Figure 7, above. Additional aspects of operation of wrench 400 will be described in reference to the end views of Figure 8 through Figure 11. In various examples, this operational activity is applicable to wrench 110 as well. Figure 8 represents a situation in which wrench 400 has clamped around a pipe 144 with jaw 405 applying a force 306 to pipe 144 through roller 402, in an engaged or gripping position. To facilitate discussion, a reference plane 450 is drawn between roller central axis 411 and the center of pipe 144, which is aligned with operational axis 409 in this example. Roller 402 is rotating in the counterclockwise direction, as indicated by arrow 304. The outer surface 426 of roller body 410 is engaging pipe 144 at a roller contact line 452, and pipe 144 is being rotated clockwise by roller 402, as indicated by arrow 308. Contact line 452 extends axially, being parallel to roller axis 411, and line 452 is straight and continuous, extending along a majority or all the length of roller 402 without interruption. No insert 215 of roller 402 is contacting pipe 144 at the time represented by Figure 8, but an insert 215 A is adjacent and is moving toward pipe 144. At least in some embodiments of wrench 400, other rollers 402 and their inserts (not shown in Figure 8) also contact pipe 144 and contribute to the pipe’s rotation. The rotation of roller 402 is indicated by arrow 304, and the rotation of pipe 144 is indicated by arrow 308. A contact plane 454 is defined to extend through contact line 452 and the center of pipe 144 (e.g., operational axis 409). With roller body 410 contacting pipe 144, a roller contact angle 455 may be defined. Roller contact angle 455 is defined to he between reference plane 450 and contact plane 454. Since these planes 450, 454 overlap the value of roller contact angle 455 is zero degrees. 02

[0044] Subsequent to Figure 8, in Figure 9, roller 402 has rotated further along direction 304, and pipe 144 has rotated further along direction 308, representing another engaged or gripping position. Roller body 410 continues to contact pipe 144, and insert 215A has moved closer to the roller contact line 452. Roller contact angle 455 maintains its zero value. But also, insert 215A has begun to engage pipe 144 at a contact line 456, so roller 402 engages the pipe at a first and a second location simultaneously, also referred to as a double contact. Contact line 456 extends axially, being parallel to insert axis 241 and roller axis 411, and line 456 is straight and continuous, extending along a majority or all the length of insert 215A without interruption. Held in a pocket 430, insert 215 A and has begun to push against the pipe. In some embodiments or some encounters with pipes of various diameters, this and subsequent interactions may cause insert 215A to rotate within pocket 430, or it causes insert 215A to bind or grip against pocket 430, which may also be described as a wedging action.

[0045] In Figure 9, roller body 410 and insert 215A engage pipe 144 simultaneously during some portion of the operation of spin wrench 400, the engagements occurring at contact lines 452, 456. Incidentally, in the two-dimensional end views of the figures, features such as axes 411, 241 and contact lines 452, 456 appear as points. Insert 215A is configured to help move the pipe in the rotational direction 308. A contact plane 458 is defined to extend through a contact line 456 and the center of pipe 144. An insert contact angle 460 is defined to lie between reference plane 450 and contact plane 458, and is measured with respect to operational axis 409. Contact angle 460 is greater than zero and lies to the left of reference plane 450 in the situation that is shown. If contact plane 458 were shown to extend through insert 215A it would intersect the central axis 241 of insert 215A, in at least some instances. Another insert contact angle 462, measured about roller axis 411, is defined to lie between reference plane 450 and a plane 464 that intersects axis 411 and contact line 456 for insert 215 A. In some embodiments, contact angle 462 varies as roller 402 rotates and has values less than one half the value of the spacing angle 434.

[0046] Subsequent to Figure 9, in Figure 10 roller 402 has rotated further along direction 304 and pipe 144 has rotated further along direction 308, representing still another engaged or gripping position. Insert 215 A continues to engage pipe 144, and contact line 456 has moved closer to reference plane 450, reducing the size of contact angles 460, 462, which remain greater than zero. Roller 402 and its central axis 411 have moved away from the pipe because insert 215 A protrudes beyond roller body outer surface 426. This movement has increased the distance between center axis 411 and the center of pipe 144, as if stretching a 02 length of reference plane 450. Roller 402 is not contacting pipe 144. As the rotation of roller 402 continues beyond the condition of Figure 10, contact angles 460, 462 decrease further. As such, Figure 9 represents the greatest value of contact angle 460.

[0047] Subsequent to Figure 10, in Figure 11 roller 402 has rotated still further along direction 304 and pipe 144 has rotated still further along direction 308, representing an additional engaged or gripping position. Contact line 456 and contact plane 458 of insert 215A have moved into alignment with reference plane 450; contact line 456 and central axis 241 intersect plane 450. Consequently, contact angles 460, 462 have reduced to zero. As the rotation of roller 402 continues beyond the condition of Figure 11, contact angle 460 begins to increase on the right side of reference plane 450. Eventually contact angle 460 on the right side of reference plane 450 achieves a value equal to the value of contact angle 460 in Figure 9, wherein angle 460 is on the left side of reference plane 450. Similarly, contact angle 462 moves to the right side of reference plane 450 and begins to increase as the rotation of roller 402 continues. Briefly at that time, insert 215A and roller body 410 both contact pipe 144, and the system transitions to contact between roller body 410 and pipe 144 only. As the rotation of roller 402 continues, the contact cycle repeats for other members of the plurality of rollers 215, starting again with a situation as described in Figure 8. In various embodiments, the maximum value of contact angle 460 ranges between 3.5 and 9 degrees. Some embodiments have a maximum value of contact angle 460 that is outside this range. While not limited to a particular theory, in general, the lower the value of contact angle 460, the higher is the chance for the roller to roll inside the pocket, and the tangent of contact angle 460 is equal to the coefficient of friction between an insert 215 and pipe 144, in at least some instances.

[0048] The operation of spin wrench 400 in Figure 8 to Figure 11 has been described with roller 402 rotating in a counterclockwise direction 304. During operation, roller 402 can also be rotated in a clockwise direction to cause a pipe 144 to rotate in a counterclockwise direction. Thus, wrench 400 can rotate roller 402 multiple revolutions about axis 411, in either of two opposite directions to cause pipe 144 to rotate multiple revolutions in either of two opposite directions about axis 409. Although various operation events have been described with respect to the one roller 402 shown in Figure 8 to Figure 11, it is to be understood that in various embodiments, the operation of wrench 400 includes the interaction of multiple motor-driven rollers 402 with pipe 144. 02

[0049] Throughout the periodic scenario described for Figure 8 to Figure 11, force 306 continues to push roller 402 toward pipe 144, with the goal of maintaining contact between them in some embodiments. Force 306 is generated by hydraulic pressure in a hydraulic piston-cylinder assembly (e.g., assembly 148 in Figure 2) or another actuator and transferred through opposing jaws 405. The pressure within hydraulic piston-cylinder assembly may pulsate or may spike and drop periodically as the contact engagement of roller 402 against pipe 144 transitions between roller body 410 and the convex surfaces 242 of multiple inserts 215. Roller 402 and its axis 411 periodically move away from and toward pipe 114 due to the intermittent contact between pipe 114 and the multiple inserts 215, pushing against or relaxing the hydraulic fluid pressure in the piston-cylinder assembly. Variation in hydraulic pressure results in variation in force 306. Higher values of force 306 generate higher frictional force to grip pipe 144. It is contemplated that some embodiments may include a controller or data acquisition system that correlates the contact angle 460 with the changes in pressure in the piston-cylinder assembly 148. In some embodiments, a hydraulic system that controls pressure for hydraulic piston-cylinder assembly 148 is configured to adjust or control hydraulic pressure supplied to assembly 148 within a preset range of pressures based on contact angle 460, based on measurement of pressure of the hydraulic fluid, or based on a prediction of how hydraulic pressure may be prone to rise and fall if unaided. Adjusting or controlling hydraulic pressure may reduce pressure pulsations or mechanical stresses for assembly 148 and wrench 110.

[0050] Considering insert 215 further, curved outer surface 242 of insert 215 is free of axially extending edges. For example, surface 242 is free of sharp edges and free of angled edges that extend axially with respect to a roller axis 211, 411 when installed in a roller body 110, 410. Such edges, if present, might bite into the surface of a pipe. In at least some embodiments, surface 242 has a smooth surface finish. Although shown as entirely convex, in some embodiments, outer surface 242 of insert 215 includes both convex and concave portions that are circumferentially spaced and extend axially.

[0051] In various embodiments disclosed herein, wrench rollers 112, 402 each include multiple cylindrical inserts 215 radially off-set from and disposed around a central axis 141, 411 of the roller. Arranged in this manner, the inserts 215 may be described as eccentric inserts.

[0052] Considering Figure 9 as an example, in some embodiments described herein, the amount or number of contacts between the rollers and pipe is increased. The simultaneous 02 engagement of insert contact line 456 and roller contact line 452 periodically during operation doubles the contact between roller 402 and pipe 144 and spreads the gripping region of roller 402 circumferentially across pipe 114, as compared to other arrangements.

[0053] As introduced earlier, for some embodiments of a spin wrench or some encounters with tubular members of various diameters, an insert may wedge between the roller and the tubular member. Taking wrench 400 as an example, wedging occurs as roller 402 rotates against pipe 144 and the engagement transitions from the roller contact line 452 to the insert contact line 456. The insert 215 may be pressed against a back portion of pocket 430. This pressing action may increase the frictional force between insert 215 and pocket 430 and may temporarily bind insert 215 in pocket 430, inhibiting insert 215 temporarily from rotating relative to roller 402. This wedging of insert 215 between roller 402 and pipe 144 may increase the grip of roller 402 against pipe 144. In various examples, this wedging occurs between pipe 144 and multiple inserts 215 on multiple rollers 402 while engaging or spinning pipe 144 in either direction, clockwise or counterclockwise, potentially increasing the grip of rollers 402 while making or breaking a threaded connection between tubular members. In some embodiments, these features can contribute to a decrease in or minimization of slippage between the rollers and the pipe while the pipe and rollers are dry or while they are wetted. In some embodiments, these features can contribute to a higher torque being transmitted from the rollers to the pipe. In some embodiments, an insert 215 rotates within pocket 430 rather than wedging, and in some embodiments, an insert 215 both rotates within pocket 430 during some of the time it engages pipe 144 and wedges within pocket 430 during another portion of the time that roller 402 engages pipe 144.

[0054] In various embodiments as described herein, rollers with inserts as gripping members may operate on a tubular member with less or minimized disturbance to the surface of the tubular member and with less or minimized potential for sparking during contact. For example, during the operation of various embodiments, the outer surfaces of a roller and its installed inserts engage a tubular member resulting in no deformation or elastic deformation of the tubular member, without causing plastic deformation. As a result, some spin wrench embodiments in accordance with this disclosure are configured to leave fewer, less severe, or no teeth marks on the tubular member than would a traditional spin wrench.

[0055] Although iron roughneck 100 in Figure 1 is mounted to operational floor 136 by an articulating arm assembly, in some embodiments, an iron roughneck built in accordance with 02 principles described herein is instead mounted to an operational floor 136 by another arrangement, such as a slidable mounting, which may include rollers on a track, as examples.

[0056] In the discussion above, spin wrenches 110, 400 were described as having multiple spin wrench rollers 112, 402, respectively, and each roller 112, 402 includes multiple inserts 215. Even so, some embodiments of a spin wrench consistent with the present disclosure include both a roller 112, 402 and also a conventional spin wrench roller that has a circumferentially continuous cylindrical outer surface and no inserts. The circumferentially continuous cylindrical outer surface may be smooth or may include a texture.

[0057] Figure 12 presents a method 500 for making and breaking threaded connections between a pair of tubular members. In various implementations, method 500 can be accomplished with an iron roughneck 100 or spin wrench 110. At block 502, method 500 includes gripping a first tubular with a torque wrench of an iron roughneck. At block 504, method 500 includes rotating a roller of a spin wrench using a motor. At block 506, method 500 includes engaging a second tubular member with the rotating roller. At block 508, method 500 includes causing a roller body of the roller and members of a plurality of inserts held by the roller body to engage alternately the second tubular member to cause the second tubular member to rotate more than one revolution in either of a first or a second direction. The result may include making or breaking a threaded connection between the first and second tubular members.

[0058] In various implementations, rotating the roller and engaging the second tubular member of blocks 504, 506 include engaging the second tubular member with the roller body and with an insert of the plurality of inserts simultaneously. In various implementations, method 500 includes achieving an axially-extending contact line between the second tubular member and the roller, wherein, while rotating the roller, the contact line moves along a surface of the roller body and is subsequently disposed on a surface of an insert of the plurality of inserts. Method 500 may include grasping the second tubular member with the torque wrench, and rotating the first and second tubular members relative to one another with the torque wrench to loosen or to tighten a threaded connection.

[0059] In various implementations, method 500 includes achieving an axially-extending first contact line between the second tubular member and the roller body during a first time duration while rotating the roller and includes achieving an axially-extending second contact line between the second tubular member and a first member of the plurality of inserts during a second time duration while rotating the roller. In various implementations, the first contact 02 line and the second contact line are geometrically continuous along a surface of the second tubular member. During the first time duration there is no contact between the second tubular member and the plurality of inserts, and during the second time duration there is no contact between the second tubular member and roller body. During ring a transition duration between the first time duration and the second time duration, both the first contact line and the second contact line are achieved simultaneously.

[0060] In various implementations, method 500 includes achieving the axially-extending first contact line between the second tubular member and the roller body during a third time duration while rotating the roller, and includes achieving an axially-extending third contact line between the second tubular member and a second member of the plurality of inserts during a fourth time duration while rotating the roller. During a transition time duration between the second time duration and the third time duration, both the first contact line and the second contact line are achieved simultaneously. In various implementations, method 500 includes wedging an insert of the plurality of inserts between the roller body and the second tubular member while rotating a roller of a spin wrench in either of two opposite directions. Wedging of the insert may occur, for example, as a result of transitioning from an engagement between the second tubular member and the roller body to an engagement between the second tubular member and the member of the plurality of inserts.

[0061] While exemplary embodiments have been shown and described, modifications thereof can be made by one of ordinary skill in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations, combinations, and modifications of the systems, apparatuses, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. The inclusion of any particular method step or operation within the written description or a figure does not necessarily mean that the particular step or operation is necessary to the method. The steps or operations of a method listed in the specification or the claims may be performed in any feasible order, except for those particular steps or operations, if any, for which a sequence is expressly stated. In some implementations two or more of the method steps or operations may be performed in parallel, rather than serially.

Claims

CLAIMS What is claimed is:

1. An iron roughneck to make and break threaded connections between a pair of tubular members, the iron roughneck comprising:

a torque wrench to grip a first tubular member;

a spin wrench to engage and rotate a second tubular member, the spin wrench comprising:

a wrench frame;

a roller supported by the wrench frame, the roller comprising:

a cylindrical roller body with a cylindrical outer surface;

a plurality of retention pockets in the roller body with pocket openings in the outer surface of the roller body; and

a plurality of inserts, each insert disposed in one of the retention pockets, wherein each insert is moveable relative to the roller body; and a motor configured to rotate the roller.

2. The iron roughneck of claim 1 wherein the retention pockets are longitudinal retention pockets disposed parallel to a longitudinal axis of the roller body, each insert comprises a cylindrical insert body with a cylindrical outer surface, and the longitudinal retention pockets comprise cylindrical inner surfaces to receive the outer surfaces of the inserts such that the inserts are configured to rotate in the retention pockets relative to the roller body.

3. The iron roughneck of claim 1 wherein the retention pockets in the roller are convex, the inserts are cylindrical and extend beyond the outer surface of the roller body, and the inserts are rotatable in the retention pockets relative to the roller body.

4. The iron roughneck of claim 1 wherein rotation of the roller against the second tubular member in either of two opposite directions causes an insert of the plurality of inserts to wedge between the roller body and the tubular member.

5. The iron roughneck of claim 1 wherein, during operation, the roller is held against the second tubular member by the frame and is rotated by the motor, and the roller body and inserts from among the plurality of inserts alternately engage the second tubular member.

6. The iron roughneck of claim 1 wherein, during operation, while the roller is held against the second tubular member by the frame and is rotated by the motor, the roller body and an insert of the plurality of inserts engage the second tubular member simultaneously.

7. The iron roughneck of claim 1 wherein the outer surface of the roller body is uniform, lacking features that would bite into the second tubular member, and wherein the outer surface of the insert body is uniform, lacking features that would bite into second tubular member.

8. The iron roughneck of claim 1 wherein the wrench frame comprises a pair of opposing first and second jaws pivotally coupled together to form the jaw opening to receive the second tubular member parallel to the operational axis; and

wherein the roller, which is a first roller, includes a roller central axis disposed parallel to the operational axis and is coupled along the first jaw;

wherein each insert of the first roller includes an outer, convex surface that extends beyond the outer surface of the roller body;

wherein the first roller extends radially into the jaw opening;

wherein the spin wrench further comprises a second roller coupled along the second jaw, the second roller comprising:

a roller central axis disposed parallel to the roughneck axis;

a cylindrical roller body with a cylindrical outer surface disposed about the roller central axis;

a plurality of axially extending retention pockets in the roller body with pocket openings in the roller surface; and

a plurality of inserts, each insert disposed in one of the retention pockets and including an outer, convex surface that extends beyond the outer surface of the roller body, wherein each insert is moveable relative to the roller body; wherein the second roller extends radially into the jaw opening.

9. A spin wrench to engage and rotate a tubular member, the spin wrench comprising:

an operational axis, along which the tubular member is to be received;

a frame disposed about the operational axis;

a first roller with a first longitudinal axis parallel to and spaced apart from the operational axis, the first roller supported by the frame;

a second roller with a second longitudinal axis parallel to and spaced apart from the operational axis and the first roller longitudinal axis, the second roller supported by the frame; and

a motor configured to rotate the rollers multiple revolutions in either of two opposite directions;

wherein each roller includes:

a cylindrical roller body with a convex outer surface disposed about the corresponding roller longitudinal axis;

a plurality of inserts, wherein each insert is disposed in one of the retention pockets, and wherein each insert includes a convex outer surface;

wherein an exposed portion of the outer surface of each insert is located beyond the outer surface of the roller body; and

wherein the second roller and second longitudinal axis are transversely movable with respect to the first roller and the first longitudinal axis to engage and rotate the tubular member.

10. The spin wrench of claim 9 wherein for each roller, the retention pockets are cylindrical, and wherein the inserts are cylindrical.

11. The spin wrench of claim 9 wherein an insert of the plurality of inserts includes an insert width extending perpendicular to the roller longitudinal axis, and wherein the exposed portion of the outer surface of the insert includes at least one eighth of the insert width.

12. The spin wrench of claim 9 wherein, during operation, while the first roller is held against the tubular member by the frame and is rotated in either of the two opposite directions by the motor, the roller body and the plurality of inserts alternately engage the tubular member.

13. The spin wrench of claim 12 wherein, during operation, the roller body and an insert of the plurality of inserts of the first roller engage the tubular member simultaneously.

14. The spin wrench of claim 12 wherein rotation of the roller against the second tubular member causes an insert of the plurality of inserts to wedge between the tubular member and the corresponding retention pocket.

15. A method for making and breaking threaded connections between a pair of tubular members with an iron roughneck, comprising:

gripping a first tubular with a torque wrench of an iron roughneck;

rotating a roller of a spin wrench using a motor;

engaging a second tubular member with the roller; and

causing a roller body of the roller and a plurality of inserts held by the roller body to engage alternately the second tubular member to cause the second tubular member to rotate more than one revolution in either of a first or a second direction.

16. The method of claim 15 wherein rotating the roller and engaging the second tubular member include engaging the second tubular member with the roller body and with an insert of the plurality of inserts simultaneously.

17. The method of claim 15 further comprising:

achieving an axially-extending contact line between the second tubular member and the roller; wherein, while rotating the roller, the contact line moves along a surface of the roller body and is subsequently disposed on a surface of an insert of the plurality of inserts.

18. The method of claim 15 further comprising:

achieving an axially-extending first contact line between the second tubular member and the roller body during a first time duration while rotating the roller; and achieving an axially-extending second contact line between the second tubular member and a first member of the plurality of inserts during a second time duration while rotating the roller.

19. The method of claim 18 wherein the first contact line and the second contact line are geometrically continuous along a surface of the second tubular member;

wherein during the first time duration there is no contact between the second tubular member and the plurality of inserts;

wherein during the second time duration there is no contact between the second tubular member and roller body; and

wherein during a transition time duration between the first time duration and the second time duration, both the first contact line and the second contact line are achieved simultaneously.

20. The method of claim 18 further comprising:

achieving the axially-extending first contact line between the second tubular member and the roller body during a third time duration while rotating the roller; and achieving an axially-extending third contact line between the second tubular member and a second member of the plurality of inserts during a fourth time duration while rotating the roller;

wherein during a transition time duration between the second time duration and the third time duration, both the first contact line and the second contact line are achieved simultaneously.

21. The method of claim 15 further comprising:

wedging an insert of the plurality of inserts between the roller body and the second tubular member while rotating the roller of the spin wrench in either of two opposite directions.

22. The method of claim 15 further comprising:

wedging an insert of the plurality of inserts within a pocket in the roller body due to transitioning from an engagement between the second tubular member and the roller body to an engagement between the second tubular member and the member of the plurality of inserts.