Torque pliers with modular integrated rotator rollers and jaws

Abstract

The present invention introduces a torque tongs 1 having a plurality of modules 25 that integrate rotator rollers and jaws into an upper tongs 3, the upper tongs being capable of directly clamping the tool joint area of a tubular drill string or other threaded equipment. The rotator rollers have a drive shaft with jaws located therebetween, the jaws being movable inwardly or outwardly relative to the rotator rollers so that the rotator rollers and jaws can engage the same tool joint but independently in sequence. The present invention eliminates the additional rotator unit typically suspended above the upper tongs 3, simplifying tripping operations and providing sufficient clamping capacity for tool joints of all sizes. In addition to the plurality of modules 25 that integrate rotators and jaws, the jaw holders are designed to be strong enough to clamp any size tool joint required in field operations.

Description

Background Art

[0001] A tong or iron roughneck device is commonly used to lower a drill string of drill pipe or other tubulars into or out of a well, commonly referred to as "tripping the drill string." A roughneck typically consists of a torque tong with lower and upper tongs that rotate relative to each other, and a rotator tong for connecting and disconnecting various drilling components, such as drill pipe and drill collars. Typically, the upper tong holds the upper tool joint, known as the "pin," and the lower tong holds the lower tool joint, known as the "box." The rotator roller typically engages only the shaft of the drill string and not the tool joint.

[0002] U.S. Patents Nos. 4,023,449, 4,348,920, and 4,765,401, issued by Boyadjieff et al., and 7,313,986, issued on January 1, 2008, by West et al., all depict torque clamps and separate spinner clamps suspended above the torque clamps. These prior art techniques generally feature a torque clamp and a spinning clamp. The spinning clamp, which is separate from the torque clamp and mounted higher on a bracket, engages not with the tool joint but with the upper column of the drill pipe joint and spins the upper joint until it is disconnected from the lower joint. Because the spinning clamp cannot approach the torque clamp sufficiently, prior art iron roughnecks cannot be used to connect and disconnect some types of drill pipe assemblies. For example, auger collars have external stabilizers along their column that could be damaged by the rollers of the spinning clamp. Other components have other variations in surface and shape that make them unsuitable for contact with the spinning rollers along their column.

[0003] U.S. Patent No. 6,776,070, issued to Mason et al. on August 17, 2004, shows a torque tong having a pair of integrated rotator rollers, wherein the jaws are formed in a confined recessed area between two sets of side rollers. Although it does disclose a pair of integrated rotators and torque tongs, the clamping jaws are formed in a very confined recessed area, which limits its clamping capacity and cannot provide the required torque capacity for tool joints of different sizes. Secondly, it is impossible to align the tool joint when the rotator is closed because the torque tong cannot maintain the same position when engaging the tool joint without repositioning the entire torque tong itself. Another problem with U.S. Patent No. 6,776,070 is that due to the limited size of the rotator rollers, it cannot provide sufficient self-spinning torque to tighten the tool joint, so the top tongs need to undergo repeated back and forth rotation cycles to tighten the tool joint connection of the drill string, resulting in prolonged field tilting time. Summary of the Invention

[0004] The present invention is directed to providing multiple modules that integrate a rotator roller and jaws into a torque clamp, allowing connection and disconnection of all types of drill strings, and all sizes of drill strings, with sufficient torque capacity required by the industry, by spinning and clamping directly on the tool joint rather than on the drill string shaft. The preferred embodiment has a triple module, but a double module is also a simplified embodiment.

[0005] Another object of the present invention is to eliminate the separate rotator tongs that depend above the torque tongs and make tripping operations simpler, faster, and more efficient.

[0006] Another object of the present invention is to center the drill string by moving the modules simultaneously in a substantially straight line toward the center of the drill string without having to reposition the entire torque clamp itself.

[0007] It is a further object of the present invention to provide sufficient spin torque so that the spinner roller can quickly spin the tool joint connection, making it tight enough that the torque clamp can then perform only a single rotation cycle to torque the connection, thereby significantly saving tripping time.

[0008] Furthermore, it is an object of the present invention to provide a means for actuating the movement of the rotator rollers and jaws in an ordered manner so that the rollers and jaws can engage with the same tool joint but in a sequential order if desired.

[0009] Additionally, it is an object of the present invention to provide a self-contained spin and torque device that interfaces with other existing backup devices to hold a housing on a drilling rig for connection or disconnection to a drill string or other threaded equipment.

[0010] The present invention introduces a torque tong featuring multiple modules integrating rotators and jaws into an upper jaw capable of directly clamping the upper tool joint area of a drill string or other threaded equipment. Preferably, two rotator rollers, located at the top and bottom, with a common drive shaft, are used, with one or more jaws and jaw holders positioned between them. The jaws and jaw holders are movable inwardly or outwardly relative to the rotator rollers, enabling the rotator rollers and jaws to engage the same upper tool joint independently of one another. This invention eliminates the need for an additional rotator unit typically suspended above the upper jaw, simplifying tripping operations and providing sufficient clamping capacity for tool joints of all sizes not possible with the prior art. In addition to the multiple modules integrating the rotator and jaws, the vertical arrangement of the jaws and jaw holders between the top and bottom rollers, along the vertical direction of the drill string, enables the jaw holder to be designed with sufficient strength to clamp any size and type of tool joint widely used in field operations. Additionally, the integrated rotator and jaws provide self-centering capability to maintain the tool joint in the center of the well.

[0011] The present invention also includes a lower tong having a plurality of clamping jaws for holding the lower tool joint of the drill bit, commonly referred to as the "box," during the tripping operation. The lower tong is stationary and does not rotate. The upper tong is supported by the lower tong and is rotatable relative to the lower tong about the axis of the drill string. The lower tong is supported by other components, which allows the lower and upper tongs to be raised and lowered together along the drill string to position the tool joint. Although the lower tong is preferred, it is not necessary to connect or disconnect it from the drill string or other threaded equipment, as other components, such as drill floor skids and other backup clamps or clamping devices, can also hold the lower tool joint of the drill string or other threaded equipment.

[0012] Other features and advantages of the present invention will become apparent from the following detailed description when read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In the drawings forming a part of this specification, there is set forth below an embodiment showing various features of the invention:

[0014] Figure 1 is a perspective view of a torque clamp according to a preferred embodiment of the present invention attached to a carrier and a positioning device;

[0015] Figure 2 is a perspective view of a preferred embodiment of a torque clamp;

[0016] Figure 3 is a perspective view of another preferred embodiment of a torque clamp;

[0017] Figure 4 is a perspective view of a preferred embodiment of a module for a torque clamp;

[0018] Figure 5 FIG. 1 is a perspective view of another preferred embodiment of a module for a torque clamp. DETAILED DESCRIPTION

[0019] Figure 1 A perspective view of a torque clamp 1 according to a preferred embodiment of the present invention is shown attached to a carrier 60 and a positioning device 61. The lower jaw of the torque clamp is attached to a carrier that can move the entire torque clamp vertically up and down. The positioning device can extend and retract the torque clamp between a parked position and a well center position.

[0020] Figure 2A perspective view of a preferred embodiment of a torque tong 1 is shown, having an upper jaw 3 at the top and a lower jaw 7 at the bottom. A hydraulic cylinder 4 is attached to both jaws and applies torque to the upper jaw 3, rotating it about its center. At least one hydraulic cylinder 4 is required. Preferably, three modules 25, each spaced 120 degrees apart, are used in the upper jaw, integrating spinner rollers and jaw teeth. These modules can be moved in and out of the tong housing body via a hydraulic cylinder or rotary actuator and engaged or disengaged with the upper tool joint, allowing the spinner rollers to clamp the tool joint. The drill string can also be aligned by simultaneously moving all modules in a generally straight line toward the center of the drill string, without repositioning the entire torque tong itself. In the present invention, the spinner rollers, with their grooved or knurled surfaces, clamp onto the tool joint, allowing them to apply a significant amount of normal clamping force directly to the tool joint, which would otherwise be impossible to apply to the string because excessive force would damage the drill string. This, in turn, allows the present invention to generate a significant amount of self-spinning torque, provided the drive motor can provide it. In the present invention, because the rotator roller and drive motor can generate sufficient torque, they can be used to replace conventional casing tongs for connecting and disconnecting casing for casing running operations. The lower tongs 7 serve as a backup device for holding the lower tool joint and typically have two or three clamping actuators. The torque tongs are connected to a torque tong carrier 60, which allows the tongs to be raised and lowered along a vertical track or guide and can also be extended or retracted with a positioning device 61, and a bracket. Rotation of the upper tongs is preferably accomplished using a hydraulic cylinder 4, a pneumatic cylinder, or an actuator, but it can also be accomplished by alternatively using a gearbox to achieve a greater degree of rotation.

[0021] Figure 3 A perspective view of another preferred embodiment of a torque tong 8 is shown, featuring an upper jaw 9 at the top and a lower jaw 10 at the bottom. A hydraulic cylinder 11 is attached to both jaws and applies torque to the upper jaw 9, rotating it about its center. At least one hydraulic cylinder 11 is required. Preferably, two modules 17 with integrated rotator rollers and jaws are used in the upper jaw. These modules can be moved in and out in opposite directions within the housing body via hydraulic cylinders or rotary actuators, engaging or disengaging the upper tool joint to allow the rotator rollers to clamp securely to the tool joint. The drill string can also be centered by simultaneously moving all modules in a generally straight line toward the center of the drill string without repositioning the entire torque tong. The lower jaw 10 serves as a backup for holding the lower tool joint and typically has two or three clamping actuators, jaws connected to a torque tong carrier 60 that allows the tong to be raised and lowered along a vertical track or guide, and jaws that can also be extended or retracted with a positioning device 61, and a bracket. The upper tong rotation is preferably done by using a hydraulic cylinder 11 or a pneumatic cylinder or actuator, but it can also be done by using a gear box instead to obtain more degrees of rotation.

[0022] Figure 4 A preferred embodiment of the module 25 integrates a rotator roller 33 and jaws 34 held by jaw retainers 28 with wedge-shaped grooves. Three modules are used, preferably spaced 120 degrees apart. At least one roller 33 is used, but preferably multiple rollers are used, as shown in the diagram. Driven by a hydraulic cylinder or piston built into the module, the roller 28 can be moved in and out relative to the roller 33 to engage or disengage one or more jaws with the tool joint. The rotator roller is driven by a shaft, which can be driven directly by a hydraulic or electric motor 35 or rotary actuator, or by a gearbox with a suitably configured gear train. In a preferred embodiment, the entire module 25 is driven by at least one hydraulic cylinder or rotary actuator 26, either inside or outside the upper jaw housing. The distal end of the cylinder or actuator 26 is connected to the jaw housing via one or more pins, bolts, or similar members. A structural frame 30 attached to the module body 31 holds the rotator roller assembly, which consists of a drive motor, drive shaft, and rollers.

[0023] Another embodiment of moving the modules can be accomplished by using a set of linkages that pivot about certain points using hydraulic cylinders or rotary actuators.

[0024] Figure 5 Another embodiment of the module 17 is an integrated rotator roller 33 and a jaw 34 held by a wedge-shaped groove. Two modules are used and move in opposite directions. A motor 35 driven by a hydraulic cylinder or piston built into the module can be moved in and out relative to the roller 33 so that one or more jaws can engage or disengage with the tool joint. There are two sets of drive shafts, each of which can be driven directly by a hydraulic or electric motor 2 or rotary actuator, or by a gearbox with a suitably configured gear set. In a preferred embodiment, the entire module is driven by at least one hydraulic cylinder or rotary actuator 26 inside or outside the pliers housing body. The ends of the cylinder or actuator 26 are connected to the pliers housing body by one or more pins or bolts or similar components. A structural frame 30 attached to the module body 31 holds the rotator roller assembly, which consists of the drive motor, drive shaft and roller.

[0025] Another embodiment of moving the modules can be accomplished by using a set of linkages that pivot about certain points using hydraulic cylinders or rotary actuators.

[0026] Although specific embodiments of the present invention have been described in detail herein, this has been done only for the purpose of explaining various aspects of the invention and is not intended to limit the scope of the invention as defined in the appended claims. Those skilled in the art will appreciate that the embodiments shown and described are exemplary and that various other substitutions, changes, and modifications may be made in the practice of the invention without departing from the scope of the invention, including but not limited to those design alternatives specifically discussed herein.

Claims

1. An upper tong comprising a plurality of modules integrating a rotator roller and a jaw into a torque tong, said torque tong being connected to or disconnected from a tool joint of a drill string or other threaded drilling equipment, said plurality of modules being movable in and out of a tong housing body, wherein: Each of said modules comprises: Module body; at least one spinner roller assembly, a structural frame attached to the module body holding the spinner roller assembly, the spinner roller assembly including at least one spinner roller and a drive shaft for driving the spinner roller; a forceps tooth holder and at least one forceps tooth held by the forceps tooth holder; means for moving the module toward or back from the tool joint to enable the rotator roller assembly to engage or disengage with the tool joint, the means for moving the module back and forth being at least one hydraulic cylinder or pneumatic cylinder or rotary actuator or electric actuator for driving the entire module inside or outside the upper caliper housing body; means for moving the jaw holder and jaws relative to the spinner roller assembly to enable the one or more jaws to engage or disengage with the tool joint; and means for rotating the spinner roller assembly; The plurality of modules are evenly distributed, and all of the modules can be moved simultaneously in a substantially straight direction toward the center of the drill string to center the drill string.

2. The upper clamp according to claim 1, wherein: The member for moving the jaw holder and the jaws is a hydraulic cylinder, a pneumatic cylinder, a rotary actuator, or an electric actuator.

3. The upper clamp according to claim 1, wherein: The means for rotating the rotator roller is a hydraulic motor or a rotary actuator or an electric actuator or a gear box having a set of gear combinations.

4. A torque clamp for connecting or disconnecting a tool joint to a drill string or other threaded drilling equipment, comprising: The upper clamp according to any one of claims 1 to 3; a housing for holding a plurality of said modules; A lower jaw with multiple teeth; as well as Means for rotating the upper jaw relative to the lower jaw to connect or disconnect the tool joint.

5. The torque clamp according to claim 4, wherein: Each of the spinner rollers has at least one roller that rotates with the drive shaft.

6. The torque clamp according to claim 4, wherein: The means for rotating the upper jaw relative to the lower jaw is at least one hydraulic cylinder or pneumatic cylinder or rotary actuator or electric actuator or a gear box with a set of gear combinations.

7. A method for disconnecting a tool joint of a drill string or other threaded equipment, using the upper tongs according to any one of claims 1 to 3, the method comprising the following steps: Moving the rotator roller and multiple modules of jaw holders and jaws integrated in the upper jaw toward the upper tool joint; extending the jaw holders and jaws and clamping them onto the upper tool joint; Moving a plurality of jaw retainers and jaws or other backup devices in the lower jaw toward and clamping the jaws to the lower tool joint; Rotate the upper torque clamp to loosen the connection; The extended jaw retainer and jaws in the upper jaw are retracted and the roller is rotated to completely loosen the tool joint.

8. A method for connecting a tool joint of a drill string or other threaded equipment, using the upper tongs according to any one of claims 1 to 3, the method comprising the following steps: Moving a plurality of jaw retainers and jaws or other backup devices in the lower jaw toward and clamping the jaws to the lower tool joint; Moving a plurality of modules of rotator rollers and jaws integrated in an upper jaw toward an upper tool joint; clamping the rollers on the upper tool joint; rotating the rollers to tighten the tool joint; extending the jaw retainer and jaws in the upper jaw to tighten the tool joint; The upper torque clamp is rotated to tighten the connection until the desired torque is achieved.

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