Heavy-load pipeline carrying equipment

Abstract

Some embodiments of the present disclosure relate to a pipe handling apparatus that includes a base, an elongate door, a pipe carrier, a lift member, and a pipe carrier extension. In some embodiments, the pipe carrier extension is operatively coupled to the pipe carrier such that when in the extended position, the pipe carrier and the pipe carrier extension may cooperatively receive, support, and move a section of two or more connected pipes between the lower surface and the upper surface. Some embodiments of the present disclosure relate to a system comprising the pipe handling apparatus and pipe rack system and a connection system wherein the system is configured to connect two or more pipes together such that the apparatus can move a length of the two or more pipes that have been connected between the lower surface and the upper surface.

Description

Technical Field

[0001] The present disclosure relates to a pipe handling device and a method of handling pipes. Specifically, the devices and methods of the present disclosure can be used to move objects between an elevated platform and a surface below the elevated platform. Background Art

[0002] Pipe handling devices are known for moving a heavy pipe section from a lower surface to an elevated surface and vice versa. Such heavy pipes are components of a pipe string used to form and complete an oil well and / or a gas well.

[0003] During drilling or well completion operations, the pipes are moved in two ways: (i) vertically, between a lower surface (which is typically the ground or floor of a rig or well completion rig) and an elevated operating level on the rig; and (ii) rotationally, whereby the pipe is moved between a substantially horizontal storage orientation and a substantially vertical operating orientation for insertion into or extraction from a well below the operating level of the rig.

[0004] To extend from the well surface towards the bottom of the well, multiple pipes are connected end to end to form a pipe string (whether drill pipe or casing, etc.). The pipes are connected together by threaded connections. For example, a first pipe can be held in a vertical position on an elevated operating level. Next, a second pipe is lifted from a low level where the pipes are stored when not in use to the elevated operating level. Then, the second pipe is positioned in line with and above the first pipe, where a pipe string assembly device located on or above the operating level of the rig rotates the second pipe to thread it onto the first pipe. Then, the first and second pipes are pushed into the well so that the second pipe occupies the previous position of the first pipe. Next, a third pipe is lifted from the low level to be positioned in line with and above the second pipe so that the second and third pipes can be threaded together. These steps are repeated until enough pipes are connected to form a connected pipe string that extends the desired distance into the well.

[0005] The weight of these heavy pipes can exceed approximately 15,000 pounds (1 pound is equivalent to approximately 0.453 kilograms). In addition to their weight, the heavy pipes are also very long. For example, a section of R1-class pipe is typically 18 to 22 feet long (1 foot is approximately 0.3048 meters), a section of R2-class drill pipe is about 27 feet to about 31 feet long, and a section of R3-class casing can be between about 38 feet and 45 feet long. Furthermore, the cross-section of these heavy pipes is typically circular, and thus, when moving the pipes between a lower surface and an elevated operating surface, these heavy pipes must be handled carefully to avoid losing control of the pipes and causing a catastrophic accident.

[0006] Since a well may require pipe strings that are tens of thousands of feet long, a significant amount of operating time spent on the rig is used to connect the individual pipe sections. Additionally, for a given well, different operations require different types of pipe strings. For example, a drilling operation may require the assembly of a drill pipe string of class R2. When the drilling operation is complete, the class R2 drill pipe string must then be disassembled, and a class R3 casing string must be assembled for the completion operation. When the completion operation is complete, an R1 class production string may then be required for the production of fluids. Since each individual pipe section is connected and disconnected by the same equipment on the elevated operating level of the rig, this type of procedure typically occurs continuously, which is very time-consuming and thus costly. Summary of the Invention

[0007] Some embodiments of the present disclosure relate to pipe handling equipment for use with an oil and gas well rig. A pipe handling equipment for use with an oil and gas well rig, the pipe handling equipment comprising: a base that can be supported by a first surface, the base including a first end and a second end; an elongate door having a first end and a second end and pivotally connected to the base at the second end, the elongate door being pivotally movable about the second end between a folded position and an extended position, and when in the extended position, the first end can be positioned adjacent to the operating level of the rig; a pipe carrier supported by the base, having a first end and a second end, and configured to receive and support a portion of at least two connected pipes; a pipe carrier extension supported by the base, the pipe carrier extension including a first end and a second end, the second end being operatively coupled to the first end of the pipe carrier, the pipe carrier extension being movable about the second end between a folded position and an extended position, and when in the extended position, the pipe carrier extension extends beyond the base and is configured to receive and support another portion of at least two connected pipes; and a lifting member supported by the base, the lifting member being pivotally connected to the pipe carrier at the first end and pivotally connected to the base at the second end by a foldable extension, and the lifting member being movable along the base toward and away from the second end of the elongate door.

[0008] Some embodiments of the present disclosure relate to a pipe handling system. The system includes: a connection system configured to connect and disconnect individual sections of pipe; and pipe handling equipment including: a base supportable by a first surface; an elongate door having a first end and a second end and pivotally connected to the base at the second end, the elongate door being pivotally movable about the second end between a folded position and an extended position, the first end being positionable adjacent to an operating deck of a rig when in the extended position; a pipe carrier supported by the base, having a first end and a second end, and configured to receive and support a portion of at least two connected sections of pipe; a pipe carrier extension supported by the base, having a first end and a second end, the second end pivotally connected to the first end of the pipe carrier, the pipe carrier extension being movable about the second end between a folded position and an extended position, and when in the extended position, the pipe carrier extension extending beyond the base and configured to receive and support another portion of at least two connected sections of pipe; and a lifting member supported by the base, pivotally connected to the pipe carrier at a first end and pivotally connected to the base at a second end by a foldable extension, and the lifting member being movable along the base toward and away from the second end of the elongate door.

[0009] Without being bound by any particular theory, the foregoing embodiments of the present disclosure may provide the benefits of a pipe handling system that reduces the amount of time for connecting and disconnecting individual sections of pipe on an operating deck of an oil and gas rig during fabrication and break-up of a pipe string. The pipe handling equipment allows multiple connected sections of pipe to be moved from a lower surface to an elevated operating deck. For example, the pipe handling equipment may provide a pipe carrier and a pipe carrier extension that are long enough to support two or three connected sections of pipe. When the pipe handling equipment is used in conjunction with a make-up (buck) unit and a pipe rack system, two or three sections of pipe can be connected and then lifted to the operating deck where the pipe string assembly equipment only needs to make one connection. In fact, the pipe handling system of the present disclosure may provide two or more parallel operations for connecting and disconnecting sections of pipe. This means that equipment on the operating deck can be freed up to perform other operations that would otherwise be delayed without the embodiments of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 Shown is a pipe handling equipment in a substantially folded position according to an embodiment of the present disclosure, wherein Figure 1 A is an isometric view of the pipe handling equipment; and Figure 1 B is a side view of the pipe handling equipment.

[0011] Figure 2Shows a pipe handling device with an elongated door in the extended position, wherein, Figure 2 A is an isometric view of the pipe handling device; and Figure 2 B is a side view of the pipe handling device.

[0012] Figure 3 Shows a pipe handling device with an elongated door in the extended position and a pipe carrier in a partially extended position, wherein, Figure 3 A is an isometric view of the pipe handling device; Figure 3 B is a side view of the pipe handling device; and Figure 3 C is a top plan view of the pipe handling device.

[0013] Figure 4 Shows a close-up view of a part of the pipe handling device, wherein, Figure 4 A shows the part of the pipe handling device located Figure 3 inside the circle "3" in B; and Figure 4 B, Figure 4 C and Figure 4 D all show the linkage system for moving the pipe carrier extension between the folded position and the extended position.

[0014] Figure 5 Shows a pipe handling device with an elongated door, a pipe carrier, and a pipe carrier extension in the extended position, wherein, Figure 5 A is an isometric view of the pipe handling device; Figure 5 B is a side view of the pipe handling device; and Figure 5 C is a top plan view of the pipe handling device.

[0015] Figure 6 Shows a lifting member, wherein, Figure 6 A is a top plan view of the lifting member in the folded position; Figure 6 B is a top plan view of the lifting member in the extended position; Figure 6 C are two isometric views of the lifting member in the folded position and the extended position; and Figure 6 D is a close-up view of the part of the lifting member marked in circle D shown in Figure 6 C.

[0016] Figure 7 Shows Figure 3 a close-up view of the components of the device, wherein, Figure 7 A is an isometric view of the pipe carrier held in the channel of the elongated door; Figure 7 B shows the part of the lifting member pivotally connected near the elongated door; and Figure 7C shows a pipe carrier supported from below by a lifting member.

[0017] Figure 8 Shows components of an actuator system, where Figure 8 A is a partially cutaway top plan view showing a part of the base with the actuator in the compressed position; Figure 8 B is showing Figure 8 A top plan view of a part of the base with the actuator of A in the extended position; and Figure 8 C is a side view of the base with a partial cutaway.

[0018] Figure 9 Is an isometric view of an example of a rig on a well site, the rig including a system using Figure 1 a pipe handler.

[0019] Figure 10 Shows Figure 9 the system of Figure 10 A is a top plan view of the system; and Figure 10 B is Figure 10 a close-up view of circle A in A. Detailed description

[0020] Embodiments of the present disclosure relate to an adjustable object handler, also referred to as a pipe handling device, a pipe handling assembly, or a catwalk, for moving objects to or from an elevated platform. Embodiments of the present disclosure can be used in the oil drilling and rigging industries, as well as other suitable industries, to assist in handling large, heavy objects, such as wellbore pipes, which are generally referred to herein as a section of pipe. Non-limiting examples of suitable pipe lengths include a single drill pipe, a single wellbore completion pipe, a single workover pipe, a section of wellbore casing, a pipe coupling, and other wellbore pipes, as understood by those skilled in the art. Handling of the wellbore pipes includes, but is not limited to, lifting and lowering the wellbore pipes between a lower location and an elevated platform. In some embodiments of the present disclosure, the elevated platform can be part of an oil and gas rig, such as a drilling rig or a completion rig (e.g., a snubbing rig or a workover rig, or other rigs as understood by those skilled in the art). Embodiments of the present disclosure relate to a mobile pipe handling device that can transfer at least two connected pipes (which can also be referred to as a section of two connected pipes or two connected pipes, etc.) from a generally horizontal storage position below an elevated platform to a near-vertical position above the elevated platform. Some embodiments of the present disclosure relate to a modular pipe handling device that can be modified with minor adjustments to facilitate use with elevated platforms of different heights. In some embodiments of the present disclosure, the device can be automatically controlled such that an operator can remotely control the system through an electronic control system, such as an electric motor, a pneumatic system, a hydraulic system, or a combination thereof).

[0021] Figure 1 An embodiment of a pipe handling device 100 in accordance with an embodiment of the present disclosure is depicted. As will be understood by those skilled in the art, the pipe handling device 100 can be positioned adjacent to an oil and gas rig, such as a drilling rig or a completion rig (not shown). The pipe handling device 100 can be made of various materials, provided that these materials include the strength characteristics required to support and move two or more connected pipes having a weight that may exceed 15,000 pounds. Generally, the components of the pipe device 100 are made of metal, metal alloy, or a combination thereof. To reduce the weight of the components of the pipe handling device 100, various weight-reducing features can be included, such as weight-reducing openings throughout each component (as shown). Those skilled in the art will understand that the components of the pipe handling device 100 are generally symmetric about a longitudinal midline. Accordingly, the following discussion will generally describe only one side of each component, but it should be understood that such a description equally applies to the opposite side of the described component unless otherwise specified below.

[0022] At least as Figure 1 A and Figure 1As shown in FIG. B, the pipe handling device 100 includes a base 10, an elongate door 20, a pipe carrier 30, a pivotable pipe carrier extension 31, and a lifting assembly 40 (as shown in FIG. Figure 5 A). The pipe handling device 100 can be in a folded position ( Figure 1 ), one or more intermediate positions (at least as shown in FIGS. Figure 2 and Figure 3 ) and a deployed position (at least as shown in FIG. Figure 5 ). As used herein, the term "stroke" refers to the partial or complete movement of one or more components of the pipe handling device 100 relative to another component. For example, when the device 100 moves from the folded position, the elongate door 20 pivotally moves through at least a portion of the stroke to one or more intermediate positions (compare FIGS. Figure 1 and Figure 2 ). When the pipe carrier 30 moves from an intermediate position to the deployed position (compare FIGS. Figure 2 and Figure 3 and FIGS. Figure 5 ), the device 100 can move through another portion (or the complete stroke) of the stroke. When the components of the pipe handling device 100 move through these different positions, a section of at least two connected pipes (not shown) can move from a substantially horizontal position near the base 10 on the pipe carrier 30 (where the device 100 is in the intermediate position shown in FIG. Figure 2 ) to a fully deployed position (at least as shown in FIG. Figure 5 ). When the section of at least two connected pipes moves from the substantially horizontal position near the base 10, as the pipe handling device 100 moves until the deployed position, the section of at least two connected pipes moves upward to approach the upper operating level of the drill rig. From this position, the section of at least two connected pipes moves through additional components of the drill rig to assume a substantially vertical position for connection to a waiting pipe section and insertion into the wellbore below the drill rig. As will be understood by those skilled in the art, the movement and function of the pipe handling device 100 can also be reversed to lower the section of at least two connected pipes from an elevated position on the pipe carrier 30 (when the pipe handling device 100 is in the deployed position) to a substantially horizontal position near the base 10 (when the pipe handling device 100 is in the intermediate position). Although the following discussion describes the movement of the pipe handling device 100 from the folded position to the deployed position for moving the section of two or more connected pipes from a substantially horizontal position to the operating level near the drill rig, those skilled in the art will understand that the reverse movement of the pipe handling device 100 is similarly contemplated herein.

[0023] The base 10 can be directly supported on a surface (not shown), such as the ground or the lower layer of a drill rig. The base 10 defines a first end 10A and a second end 10B, and these two ends together define the longitudinal axis of the base 10. In some embodiments of the present disclosure, the base 10 can be elongated along the longitudinal axis; however, this is not necessary. The base 10 is configured to support the elongated door 20, the pipe carrier 30, the pipe carrier extension 31, and the lifting assembly 40, while these components support and move a section of two or more connected pipes between the lower surface and the upper surface.

[0024] At least as Figure 1 A and Figure 1 shown in B, the base 10 can be operatively coupled and support the elongated door 20 at least through a coupler 22 (such as a triangular linker). The elongated door 20 can also be referred to as a V-shaped door and has a first end 20A and a second end 20B, and these two ends together define the longitudinal axis of the elongated door 20.

[0025] Also as Figure 2 shown, the base 10 includes a plurality of pipe rack arms 12. Figure 2 The non-limiting example shown depicts five pipe rack arms 12A, 12B, 12C, 12D, and 12E; however, more or fewer pipe rack arms 12 can be utilized depending on the actual length of the two or more connected pipes that the device 100 is moving. As further discussed below, the pipe rack arms 12 are configured to cooperate with a pipe indexing system to generally receive a section of two or more connected pipes from one side of the base 10 and guide the section of two or more connected pipes to rest on the pipe carrier 30.

[0026] Figure 2 Figure A shows the device 100 in an intermediate position, where the elongated door 20 is in an extended position, and the elongated door occupies this extended position through a pivotal movement around a pivot assembly 21 (see Figure 2 Figure B), and the pivot assembly is positioned between the second end 10B of the base 10 and the second end 20B of the elongated door 20. Figure 2B also shows the elongated door 20 in the extended position, at which the first end 20A can be positioned adjacent to a part (not shown) of the upper operating layer of the drill rig. In some embodiments of the present disclosure, the elongated door 20 may be composed of two bodies 20C and 20D, which are connected to each other by a transverse member (not shown) and define a guiding channel 20E therebetween. The guiding channel 20E may also include a bottom plate defined by a transverse member extending between the inner sidewalls of the bodies 20C and 20D. The guiding channel 20E is configured to receive a part of the pipe carrier 30 therein and restrict the lateral movement of the pipe carrier 30 when a part of the pipe carrier 30 moves along (upward or downward) the elongated door 20. In other embodiments of the present disclosure, the guiding channel 20E may be defined by a single body or more than two bodies.

[0027] The pipe carrier 30 includes a first end 30A and a second end 30B, which together define a longitudinal axis of the pipe carrier 30 (see Figure 3 A). The pipe carrier 30 may also include a slide plate assembly 34 positioned near the first end 30A of the pipe carrier 30. As will be understood by those skilled in the art, the slide plate assembly 30 may be slidably movable along the longitudinal axis of the pipe carrier 30. The slide plate assembly 30 is configured to receive and releasably fix the ends of the section of two or more connected pipes. Thus, in some embodiments of the present disclosure, the slide plate assembly 34 may also be slidably movable along the longitudinal axis of the extension 31. When the slide plate assembly 30 moves on the pipe carrier 30 from near the base 10 to near the first end 20A of the elongated door 20 in the extended position, the slide plate assembly may restrict the longitudinal movement of the section of two or more connected pipes.

[0028] In some embodiments of the present disclosure, the pipe carrier 30 may include at least a pair of safety bars 41. The safety bars 41 may be rotatably coupled to each side of the pipe carrier 30, and when rotated to the extended position, the safety bars 41 are configured to restrict or reduce the lateral movement of the section of at least two connected pipes when moving between the lower surface and the upper operating surface on the pipe carrier 30. For example, the safety bars 41 may help maintain the position of the section of pipes within the pipe carrying groove 37. Figure 4 A shows an example of the safety bar 41 in the retracted position and the extended position (shown as the dashed feature 41A).

[0029] Figure 1 Also shown is the pipe carrier extension 31 in the folded position. The pipe carrier extension 31 includes a first end 31A and a second end 31B. In the folded position, the pipe carrier extension 31 may be positioned above the base 10 (see Figure 1A). Specifically, the first end 31A can be positioned above the base 10 and above the pipe carrier 30. The second end 31B is pivotally connected to the base 10, near the second end 10B, such that the extension 31 can pivot about the second end 31B to move into the extended position (see Figure 2 ). When in the extended position, the extension 31 can be functionally aligned with the longitudinal axis of the pipe carrier 30, where the second end 31B is coupled to the first end 30A of the pipe carrier 30. The pipe carrier extension 31 includes many of the same components as the pipe carrier 30, such that when the pipe carrier 30 and the extension 31 are received and moved from a low level to a high level, a section of two or more connected pipes can be supported together.

[0030] For clarity, the section of two or more connected pipes refers to two or more connected pipes for an oil well and / or a gas well. These pipes are heavy, and the weight can exceed about 15,000 pounds (one pound is equivalent to about 0.45 kilograms). In addition to their weight, these heavy pipes are also long. For example, typical examples of pipes for oil wells and / or gas wells include: R1-class pipes, one section of which is about 18 to about 24 feet (one foot is about 0.305 meters); R2-class drill pipes, one section of which is about 27 feet to about 31 feet long; and R3-class casings, one section of which can be between about 38 feet and 45 feet long. Furthermore, the cross-section of these heavy pipes is generally circular, and thus, when moving the pipes between the lower surface and the elevated operating surface, these heavy pipes must be handled carefully to avoid losing control of the pipes and causing a catastrophic accident. Embodiments of the present disclosure provide an apparatus 100 that is configured to receive and move a section of at least two connected pipes between a low level and a high level. Some embodiments of the present disclosure relate to an apparatus 100 that is configured to receive and move a section of at least two connected pipes that is between about 30 feet and about 150 feet long. For example, when using R1-class pipes, the apparatus 100 can receive and move a section of two connected R1-class pipes that is between about 36 feet and about 48 feet long. The apparatus 100 can also receive and move a section of three connected R1-class pipes that is between about 54 feet and about 72 feet long. When using R2-class pipes, the apparatus 100 can receive and move a section of two connected R2-class pipes that is between about 54 feet and about 62 feet long. The apparatus 100 can also receive and move a section of three connected R2-class pipes that is between about 81 feet and about 93 feet long. When using R3-class pipes, the apparatus 100 can receive and move a section of two connected R3-class pipes that is between about 76 feet and about 90 feet long. The apparatus 100 can also receive and move a section of three connected R3-class pipes that is between about 114 feet and about 135 feet long.

[0031] Figure 3 A andFigure 3 Figure B shows different views of the pipe assembly 100, where the elongated door 20 is in the extended position, and the pipe carrier 30 and the lifting member 40 are in the intermediate position. As will be further described below, the actuator system 80 can be used to move the pipe carrier 30 towards and away from the first end 20A of the elongated door 20. When this occurs, the lifting member 40 supports the pipe carrier 30 from below, so that the second end 30B of the pipe carrier 30 can slide up and down the elongated door 20, for example, laterally constrained by the side wall 20E of the guide channel, as further discussed below.

[0032] The second end 30B of the pipe carrier 30 includes a first support surface 38A, which is positioned to rest at least against the bottom plate of the guide channel 20E when the pipe carrier 30 moves along the elongated door 20. In some embodiments of the present disclosure, the first support surface 38A may include one or more rotatable members, such as wheels or rollers, to facilitate the movement of the pipe carrier 30 along the guide channel 20E.

[0033] Figure 4 A close-up view of a part of the device 100 is shown, where the second end 31B of the extension 31 is operatively coupled to the pipe carrier 30. In some embodiments of the present disclosure, this part of the device 100 includes a lifting system 33, which is configured to lift the first end 31A of the carrier extension 31. The lifting system 33 includes at least one rolling member 33A and a ramp member 33B (see Figure 4 Figure A). The rolling member 33 is connected to the lower surface of the pipe carrier 30 or the pipe carrier extension 31 or both. The rolling member 33 is configured to rotate and assist the pipe carrier 30 and the pipe carrier extension to move along the ramp member 33B. The ramp member 33B can be positioned within the housing space 11 defined by the base 10 (see Figure 8C). The ramp member 33B may have a first portion that is substantially parallel to the longitudinal axis of the base 10 and a second portion that is angled α away from being parallel to the longitudinal axis of the base 10. In some embodiments of the present disclosure, the angle α is substantially constant along the length of the second portion; however, in other embodiments, the second portion may include different angles. One end of the first portion of the ramp member 33B may be defined by a shoulder 11A positioned at the first end 10A of the base 10. The first portion of the ramp member 33B extends to the second portion. The second portion is angled α and may extend to be adjacent to the upper surface of the base 10. Such that when the carrier extension 31 is moved to the extended position, and when the pipe carrier 30 and the carrier extension 31 are moved horizontally and vertically towards the elongated door 20, the rolling member 33A will move along the first portion of the ramp member 33B and then begin to advance upward along the second portion of the ramp member 33B. As the rolling member 33A advances upward, the rolling member will also vertically lift and lower the pipe carrier 30 and the carrier extension 31. This vertical lifting and lowering will allow the first end 31A of the carrier extension 31 to also vertically lift and lower in order to avoid engaging and penetrating into the surface of the support base 10. When the pipe carrier 30 and the carrier extension 31 return to the folded position, the rolling member 33A will move along the ramp member 33B and abut against the shoulder 11A. As will be understood by those skilled in the art, when the carrier extension 31 is in the extended position, the distance that the first end 31A of the carrier extension 31 extends away from the first end 10A of the base 10 will determine the amount of lifting and lowering required to avoid contacting the surface of the support base 10. Thus, the angle α and the length of the second portion of the ramp member 33B can be designed to achieve this goal while considering the mechanical advantage obtained by achieving vertical lifting and lowering using the ramp member 33B. As will be understood by those skilled in the art, the lifting system 33 may include a plurality of rolling members 33A and a plurality of ramp members 33B positioned within or outside the housing space 11, which together may contribute to providing vertical lifting of the first end 31A.

[0034] Figure 4 B, Figure 4 C and Figure 4 D illustrate the carrier extension 31 moving relative to the pipe carrier 30 through three positions: the folded position ( Figure 4 B), the intermediate position ( Figure 4 C), and the extended position ( Figure 4D). In some embodiments of the present disclosure, the movement of the carrier frame extension 31 can be a pivotal movement about the first end 30A of the pipe carrier frame 30 caused by the linkage system 35. The linkage system 35 can be used in various applications that require moving a first member from a first position substantially parallel to a second member to a second position that is also substantially parallel but coaxial with the second member (in addition to moving the carrier frame extension 31 between a folded position and an extended position), where such movement is about a pivot point. In Figure 4 B, Figure 4 C, and Figure 4 D, non-limiting examples, the linkage system 35 includes a first actuator 35A, a second actuator 35B, and a linkage member 35C. The actuators 35A and 35B can be hydraulically driven, pneumatically driven, electronically driven, or a combination thereof. Each of the actuators 35A and 35B can be a reciprocating actuator that can move between a retracted position and an extended position. In some embodiments of the present disclosure, the actuators 35A and 35B are hydraulic cylinders driven by the power system of the device 100, which will be further described below. The linkage member 35C is configured to facilitate the pivotal movement of the carrier frame extension 31 about the first end 30A. For example, one end of the actuator 35A can be rotatably coupled to the sidewall of the pipe carrier frame extension 31, while the other end is rotatably coupled to the linkage member 35C. Similarly, the actuator 35B can be rotatably coupled to the sidewall of the pipe carrier frame 30 at one end, while the other end is rotatably coupled to the linkage member 35C, substantially opposite the position where the actuator 35A is coupled. The linkage member 35C can be pivotally coupled to each of the sidewalls of the pipe carrier frame 30 and the pipe carrier frame extension through one or more pivot members. The pivot member can be a pivot pin or a handle that extends from the sidewall of the pipe carrier (or the pipe carrier frame extension, as the case may be) and is received in a pivot opening defined by the linkage member 35C, or vice versa. In operation, in some embodiments of the present disclosure, when the pipe carrier frame extension 31 is in the folded position, both the actuators 35A and 35B can be extended (see Figure 4 B). To move the pipe carrier frame extension 31 into an intermediate position, the actuator 35B can be retracted, causing the linkage member 35C to rotate and the pipe carrier frame extension 31 to pivot about the first end 30A of the pipe carrier frame 30 (see Figure 4 C). To move the pipe carrier frame extension 31 into the extended position, the actuator 35A can then be retracted, pulling the pipe carrier frame extension 31 into the extended position (see Figure 4 D).

[0035] In other embodiments of the present disclosure, the carrier frame extension 31 can be operatively coupled to the pipe carrier frame 30 by another mechanism. For example, the carrier frame extension 31 can be configured to be received in the housing space 11 of the base 10 or around a portion of the base 10 in a nested configuration. In other examples, the carrier frame extension 31 can be operatively connected to the pipe carrier frame 30 by a pivot hinge such that the carrier frame extension 31 can pivot about the pivot hinge and move to a folded position adjacent to the sidewall of the pipe carrier frame 30 or the base 10.

[0036] Also as Figure 5 shown, the pipe carrier frame 30 can further include an upper carrier frame extension 36 extending from the second end 30B of the pipe carrier frame 30. In some embodiments of the present disclosure, the upper carrier frame extension 36 can be pivotally connected to the second end 30B, such as at a pivot point 31. In some embodiments of the present disclosure, the upper carrier frame extension 36 can include a second support surface 38B that is positioned to bear at least against the bottom plate of the guide channel 20E when the pipe carrier frame 30 moves along the elongated door 20. In some embodiments of the present disclosure, the second support surface 38B can include one or more rotatable members, such as wheels or rollers, to facilitate the movement of the upper carrier frame extension 36 along the guide channel 20E. Figure 7 A shows the second end of the pipe carrier frame 30, where the upper carrier frame extension 36 acts as the second support surface 38B when the pipe carrier frame 30 is grasped within the guide channel 20E near the first end 20A of the elongated door 20.

[0037] In some embodiments of the present disclosure, the pipe carrier frame 30 can be held at the first end 10A of the elongated door 20 and not exceed this first end, where the upper carrier frame extension 36 no longer bears against the elongated door 20, while the first support surface 38A abuts a portion of the first end 20A of the elongated door 20 (see Figure 5 ). The first end 20A of the elongated door 20 can define a first shoulder that can cooperate with a second shoulder defined by the pipe carrier frame 30 to act as a stop and hold the pipe carrier frame 30 grasped within the guide channel 20E.

[0038] In some embodiments of the present disclosure, the first end 10A of the base 10 is configured to house a power system. The power section is configured to receive input commands from an operator and convert those commands into movement commands sent to various components of the pipe handling device 100. The user commands can be in the form of electronic signals that are converted into movement commands by a controller unit. In some embodiments of the present disclosure, the controller unit can convert an electronic command signal from a user into a hydraulic command transmitted through one or more hydraulic circuits of the pipe handling device 100. For example, the power system can also include an electric motor operatively connected to a hydraulic drive unit. The hydraulic drive unit is in fluid communication with a hydraulic fluid reservoir such that the hydraulic drive unit can control the flow of hydraulic fluid to and from the reservoir by controlling the position of one or more hydraulic valves. As will be understood by those skilled in the art, the power system can operate in a manner similar to known programmable logic controller-controlled hydraulic drive systems. Examples of some components that can be moved by the power system include: a long door 20 pivoting between a folded position and an extended position, an extension 31 pivoting between a folded position and an extended position, a pipe rack arm 12 for moving along the long door 20, a pipe carrier 30 and the extension 31, a pipe kicker system, and components of the actuator system 80 (as will be further described hereinafter in this document).

[0039] The pivotal movement of the long member 20 relative to the second end 10B of the base 10 is due to the action of a pivot assembly 21 that includes a pivot point, one or more first actuators (such as one or more hydraulic cylinders) bearing against a portion of the second end 20B of the long door 20 and a coupler 22, and one or more second actuators (such as one or more hydraulic cylinders) bearing against a portion of the second end 10B of the base 10 and the coupler 22. Either the first actuator or the second actuator can extend to provide a first part of the stroke to move the long door 20 from the folded position. Then, the other actuator (i.e., the second actuator 26B or the first actuator 26A, as the case may be) can extend to provide a second part of the stroke to move the long door from an intermediate position to a fully extended position. During the first and second parts of this stroke, the second end 20B of the long door 20 pivots about the pivot point 28 relative to the second end 10B of the base. The pivot point 28 can include a pivot connector (such as a pin) that mates within a component defined by both the base 10 and the long door 20 for pivotally coupling (which can also be referred to as pivotally connecting) the base 10 and the long door 20.

[0040] Either or both sides of the pipe carrier 30 may include one or more safety bars, and the pipe carrier 30 may define a pipe carrier groove 37 extending along the longitudinal axis of the pipe carrier 30. In some embodiments of the present disclosure, the extension 31 also includes one or more safety bars on either or both sides. The pipe carrier groove 37, the safety bars, and the skate assembly 34 cooperate to restrict the movement of the section of pipe carried on the pipe carrier 30 and the extension 31. The apparatus 100 may also include a safety bar linkage that operatively links the rotation of the safety bars on the same side of the pipe carrier groove 37 to allow the section of pipe to enter onto or leave the pipe carrier 30 on either side, and optionally enter onto or leave the extension 31.

[0041] As Figure 5 and Figure 6 shown, the lifting member 40 includes a first end 40A and a second end 40B, which together define the longitudinal axis of the lifting member 40. The lifting member 40 is slidably and rotatably movable within the base 10. The first end 40A of the lifting member 40 is pivotally connected near the first end 30A of the pipe carrier 30. The second end 40B of the lifting member 40 is pivotally connected to the base 10 near the second end 10B through one or more pivotable connections 44. In some embodiments of the present disclosure, the lifting member 40 includes a lifting extension 43 that extends beyond the second end 40B of the lifting arm 40 to pivotally connect to a portion of the base 10 or a portion of the second end 20B of the elongated door 20, or both. The lifting extension 43 may be reversibly folded to allow the lifting member 40 to advance and contract away from the second end of the base 10B while the second end 40B of the lifting member 40 is held in place by one or more pivotable connections of the extension 43. In operation, as the pipe carrier 30 moves upward along the elongated door 20, the lifting member 40 slides toward the second end 10B of the base 10, and this causes the lifting extension 43 to fold, thereby shortening the overall length of the lifting member 40. When the lifting member 40 travels as far as possible along the base 10 toward the second end 10B (e.g., because there is no further room for folding), then the second end of the lifting assembly 40B forms a pivot point with the second end 10B or the second end 20B or both, as appropriate. As Figure 6As shown in DE, the lifting extension portion 43 may define one or more pivotable connection portions 44 and shoulders 45. The shoulder 45 is configured to prevent further folding of the lifting member 40 such that when the second end 40B abuts the shoulder 45, continued upward movement of the pipe carrier 30 along the elongated door 20 causes the lifting member 40 to pivot about one or more pivotable connection portions 44 near the second end 40B. In some embodiments of the present disclosure, the lifting member 40 and the lifting extension portion 43 are arranged in a nested configuration such that when the lifting member 40 slides toward the second end 20B of the elongated door 20, at least a portion of the lifting extension portion 43 is received within the second end 40B, or vice versa. In other words, the lifting extension portion 43 and the second end 40B may be arranged telescopically to allow reversible folding of the lifting member 40. However, as those skilled in the art will appreciate, other mechanisms or materials may be employed to provide reversible foldability of the lifting member 40.

[0042] Since the first end of the lifting member 40A is pivotally connected to the first end 30A of the pipe carrier 40, the first end of the lifting member 40A is lifted upward in a pivotal and arcuate manner to a position that supports the pipe carrier when the pipe carrier 30 is held in the extended position. This is another way in which embodiments of the present disclosure can provide full capture of the pipe carrier 30 when the pipe carrier 30 moves up and down the elongated door 20. Additionally, when the pipe carrier 30 is held at the first end 20A and does not exceed that first end, the longitudinal axis of the lifting member 40 may be at an angle α less than 90 degrees (i.e., less than vertical), which also helps to capture the pipe carrier 30 within the carrier slot 20E.

[0043] Figure 7 FIG. A shows a close-up view of the second end 40B of the lifting member 40 when the second end 30B of the pipe carrier 30 is captured within the carrier slot 20E of the elongated door 20. In this position, the upper carrier extension 36 may extend toward the operating level of the drill to facilitate movement of the section of pipe from the pipe carrier to the operating level and vice versa. In some embodiments of the present disclosure, the first support surface 38A of the pipe carrier 30 is held at the first end 20A of the elongated door 20 and does not exceed that first end. This is one way to capture the pipe carrier 30 during all movements between the folded and extended positions, and vice versa.

[0044] Figure 7 FIG. B shows a close-up view of the second end 40B of the lifting member 40 when the second end 30B of the pipe carrier 30 is captured within the carrier slot 20E of the elongated door 20. Figure 7 FIG. C shows a close-up view of the first end 30A of the pipe carrier 30 when the lifting member 40 pivots and moves arcuately to support beneath the pipe carrier 30.

[0045] Figure 7 C also shows that the first end of the pipe carrier 30A includes a third support surface 37. When the pipe carrier 30A begins to move along the carrier slot 20E or when the pipe carrier completes its movement to the folded position, the third support surface 37 bears against a portion of the base 10. In some embodiments of the present disclosure, the third support surface 37 includes one or more rotatable members 39, such as one or more wheels or rollers.

[0046] Figure 8 A, Figure 8 B and Figure 8 C depict aspects of the actuator system 80, which at least includes an actuator, a shiv, and a cable, wherein the system is used to move the pipe carrier 30 along the elongate door 20. Figure 8 A shows at least one actuator 62 that can be reversibly extended within the housing 11 of the base 10 (as Figure 8 shown in C). The actuator 62 can move generally along the longitudinal axis of the base 10. Fixed to the end of the actuator 62 closest to the first end 10A is a first pulley 64 (note that Figure 8 A and Figure 8 B are partial cross-sectional views, and that is why only one pulley is depicted). In some embodiments of the present disclosure, the actuator 62 is a hydraulic cylinder that is part of a hydraulic circuit of the power system. Thus, the flow of hydraulic fluid into the hydraulic cylinder causes the actuator 62 to extend and the first pulley 64 to move toward the first end 10A of the base 10. Figure 8 A shows the actuator 62 in a non-extended (compressed) position, and Figure 8 B shows the same view with the actuator 62 extended, so the first pulley 64 is no longer visible.

[0047] Figure 8 C shows a set of second pulleys 66 positioned near the second end 10B of the base 10. A third pulley 68 is positioned near the first end of the elongate door 20 (see Figure 2B). A cable (not shown) is fixed at a cable fixing point 73 on the base 10 at one end and at a cable fixing point on the pipe carrier 30 at the opposite end. Between the two fixing points 72, the cable 70 extends at least partially around a first pulley 64 (at one end of the actuator 62), at least partially around a second pulley 66 (near the second end 10B), and at least partially around a second pulley 68. Such that when the actuator 62 extends, the cable 70 pulls the pipe carrier 30 to move, in this case upward along the elongated door 20. If the actuator 62 moves towards the non-extended position, the cable 70 will allow the pipe carrier 30 (under the action of gravity, its own weight) to move along the elongated door 20, in this case downward. As those skilled in the art will understand, the first pulley 64, the second pulley 66, and the third pulley 68 can each be two or more pulleys positioned as described above.

[0048] In some embodiments of the present disclosure, the elongated door 20 may include one or more connector plates configured to releasably receive one or more connectors, such as bolts, therethrough. The connector plates are configured to fix different longitudinal portions of the elongated door 20 together. The connector plates allow adjustment of the length of the elongated door 20, such that the pipe handling device 100 is modular and can be used with rigs having different operating layer heights.

[0049] As Figure 9 and Figure 10 shown, the device 100 can be used with a system 200, which can be used with a rig 300 for assembling and disassembling a pipe string that can extend into a well (not shown) located below the rig 300. The system 200 is configured to receive a first pipe 500A and a second pipe 500B from a pipe rack system 202, which is configured to hold separate multi-section pipes 500. The term single pipe may also be referred to herein as a section of pipe or a pipe section. The system 200 is further configured to threadedly connect the first pipe 500A and the second pipe 500B via a connection system 204 to form a section of at least two connected pipes 500C. As those skilled in the art will understand, the pipe rack system 202 can provide multiple first pipes 500A and second pipes 500B so that the system 200 forms multiple sections of at least two connected pipes 500C.

[0050] The pipe rack system 202 may include a first rack 202A configured to receive and hold separate multiple pipes 500 and advance a single pipe 500 from the first rack 202A into a transition rack system 202B. For example, the first rack 202A may be inclined such that the end of the first rack 202A closest to the transition rack system 202B is lower than the opposite end of the first rack 202A. The lower end may include a positioning system, such as one or more positioning gates, for controllably controlling the rolling movement of the pipe from the first rack 202A onto the transition rack system 202B. The transition rack system 202B may be adjustable in terms of height and horizontal position such that when the transition rack system receives a pipe from the first rack 202A, the transition rack system may adjust the position of the received pipe for delivery to a connection system 204.

[0051] In some embodiments of the present disclosure, the connection system 204 may include a make-up machine 204A configured to receive a pipe from the transition rack system 202B along the longitudinal axis of the pipe such that one end of a first pipe 500A is positioned within the make-up machine 204A. Next, the system 200 may transport a second pipe 500B, one end of which is positioned within the make-up machine 204A, such that the make-up machine 204A may threadedly connect the first pipe 500A and the second pipe 500B to form a section of at least two connected pipes 500C. Once connected, the section of at least two connected pipes 500C may be laterally rolled out (about its longitudinal axis) from the make-up machine 204A to a pipe kicker system 206. The pipe kicker system 206 is positioned between the make-up machine 204A and the device 100. The pipe kicker system 206 is configured to control the rolling movement of the section of at least two connected pipes 500C between the connection system 204 and the device 100 such that the section 500C may be placed on a pipe carrier 30 for movement from the lower surface of the drill 300 to the upper operating surface. The pipe kicker device 206 may include one or more pipe positioning stop pins, one or more pipe positioners, and one or more pipe kickers.

[0052] In some embodiments of the present disclosure, the system 200 is configured to connect three separate pipes together to form a section of three connected pipes and then receive the section of three connected pipes on the device 100 for movement between the low level 300A and the upper operating layer 300B of the drill 300.

[0053] Figure 9 The elongated door 20 is shown in the extended position and adjacent to the elevated operating layer 300B of the drill 300. As will be understood by those skilled in the art, the system 200 may also be configured to connect a third pipe to the section of connected first pipe 500A and second pipe 500B such that the section of at least two connected pipes 500C includes three sections of connected pipes.

[0054] As will also be understood by those skilled in the art, system 200 is also configured to receive from the rig 300 a section of at least two connected pipes. For example, the rig 300 may position the section of at least two connected pipes on the pipe carrier 30, and the device 100 may operate as described above to lower the received section of at least two connected pipes to the same level as the connection 204, such that the section of at least two connected pipes can be disconnected and disassembled into individual pipes by reversing the action of the make-up machine 204A. System 200 is also configured to move the individual pipes to a pipe storage tub 202 for storage until further use.

[0055] As will be understood by those skilled in the art, system 200 provides the ability to connect and disconnect individual pipe sections via the connection system 204. What this means is that the components of the rig 300 do not need to be dedicated to connecting and disconnecting each individual threaded connection required to assemble and disassemble an entire pipe string. Instead, the rig 300 can be used to connect or disconnect every other (every second) or every third connection. For example, the rig 300 only needs to connect each section of at least two connected pipes to assemble the pipe string, and the rig 300 only needs to disconnect each section of at least two connected pipes to disassemble the pipe string. Since the device 100 is configured to move the section of at least two connected pipes between the low level of the rig 300 and the upper operating level, the connection system 204 can be used to connect and disconnect sections of at least two connected pipes 500C.

[0056] Some embodiments of the present disclosure relate to pipe handling equipment for use with an oil and gas well rig. The pipe handling equipment includes a base, an elongate gate, a pipe carrier, and a lifting member. The base can be supported by a first surface. The elongate gate includes a first end and a second end, and is pivotally connected to the base at the second end. The elongate gate can pivotally move between a folded position and an extended position about the second end. When the elongate gate is in the extended position, the first end can be positioned adjacent to the operating level of the rig. The pipe carrier includes a first end and a second end, is supported by the base, and is configured to receive and support an elongate pipe. The lifting member is supported by the base, is pivotally connected to the pipe carrier at the first end, and is pivotally connected to the base at the second end by a collapsible extension. The lifting member can move along the base toward and away from the second end of the elongate gate. When the lifting member moves toward the second end of the elongate gate, the collapsible extension folds, forming a pivot point and causing the first end of the lifting member to move upwardly and arcuately toward the elongate gate.

[0057] Additional embodiments of the present disclosure relate to pipe handling equipment for use with an oil and gas well drilling rig. The pipe handling equipment includes a base, an elongate gate, a pipe carrier, and a lifting member. The base is supportable by a first surface. The elongate gate includes a first end and a second end and is pivotally connected to the base at the second end. The elongate gate is pivotally movable about the second end between a folded position and an extended position. When the elongate gate is in the extended position, the first end is positionable adjacent to the operating level of the drilling rig. The pipe carrier is supported by the base and includes a first end and a second end, and is supported by the elongate gate and configured to receive and support an elongate pipe. The second end includes a support surface movable along the elongate gate. The lifting member is supported by the base and is pivotally connected to the pipe carrier at the first end and pivotally connected to the base at the second end. The lifting member is also movable along the base toward and away from the second end of the elongate gate. When the lifting member moves toward the second end of the elongate gate, the lifting member moves upwardly and arcuately to lift the second end of the pipe carrier toward the first end of the elongate gate and not beyond the first end.

[0058] Additional embodiments of the present disclosure relate to pipe handling equipment for use with an oil and gas well drilling rig. The pipe handling equipment includes a base, a power section, an elongate gate, a pipe carrier, and a cable. The base is supportable by a first surface. The base includes a first end and a second end and is configured to house an actuator that includes a first pulley connected thereto. The actuator is configured to move between a retracted position and an extended position. The power section is configured to move the actuator between the retracted position and the extended position. The elongate gate includes a first end and a second end and is pivotally connected to the base at the second end. The elongate gate is pivotally movable about the second end between a folded position and an extended position. When the elongate gate is in the extended position, the first end is positionable adjacent to the operating level of the drilling rig. The elongate gate also includes a second pulley positioned near the second end and a third pulley positioned near the first end. The pipe carrier includes a first end and a second end and is configured to receive and support an elongate pipe. The cable is connected to the base at the first end and to the carrier arm at the second end. The cable also extends around a portion of the first pulley, around a portion of the second pulley, and around a portion of the third pulley. When the actuator moves toward the extended position, under the control of the power section, the cable travels around at least a portion of the first pulley, at least a portion of the second pulley, and at least a portion of the third pulley to move the second end of the pipe carrier upwardly toward the first end of the elongate gate.

[0059] Additional embodiments of the present disclosure relate to pipe handling equipment for use with an oil and gas well drilling rig. The pipe handling equipment includes a base, an elongate gate, a coupler, a first actuator, a second actuator, and a power section. The base is supportable by a first surface. The elongate gate includes a first end and a second end and is pivotally connected to the base at the second end. The elongate gate is pivotally movable about the second end between a folded position and an extended position. When the elongate gate is in the extended position, the first end is positionable adjacent to an operating level of the drilling rig. The coupler is positioned between the base and the second end. The first actuator is operatively coupled to a first end of the coupler and the elongate gate. The second actuator is operatively coupled to a second end of the coupler and the base. The power section is configured to move both the first actuator and the second actuator between a retracted position and an extended position. Movement of the first actuator moves the elongate gate through a first portion between the folded position and the extended position, and wherein movement of the second actuator moves the elongate gate through a second portion between the folded position and the extended position.

Claims

1. A pipe handling device for use with an oil and gas well drilling rig, the pipe handling device comprising: (a) A base that can be supported by a first surface, the base including a first end and a second end; (b) An elongate door having a first end and a second end and pivotally connected to the base at the second end, the elongate door being pivotally movable about the second end between a folded position and an extended position, and when in the extended position, the first end being positionable adjacent to the operating level of the drilling rig; (c) A pipe carrier supported by the base, having a first end and a second end, and configured to receive and support a portion of at least two connected pipes; (d) A pipe carrier extension including a first end and a second end, the second end being operatively coupled to the first end of the pipe carrier, the pipe carrier extension being movable about the second end between a folded position and an extended position, and when in the extended position, the pipe carrier extension extending beyond the base and being configured to receive and support another portion of at least two connected pipes; and (e) A lifting member supported by the base, the lifting member being pivotally connected to the pipe carrier at a first end and pivotally connected to the base at a second end by a foldable extension, and the lifting member being movable along the base toward and away from the second end of the elongate door.

2. The device according to claim 1, further comprising a linkage system configured to operatively couple the pipe carrier extension to the first end of the pipe carrier.

3. The apparatus according to claim 2, wherein, The linkage system includes an actuator and linkage members, wherein the actuator is configured to pivot the pipe carrier extension about one or more pivot points of the linkage members.

4. A system for handling a section of at least two connected pipes, wherein, The system includes: (a) A connection system configured to connect and disconnect individual pairs of pipes; (b) A pipe handling device including: (i) A base that can be supported by a first surface; (ii) An elongate door having a first end and a second end and pivotally connected to the base at the second end, the elongate door being pivotally movable about the second end between a folded position and an extended position, and when in the extended position, the first end being positionable adjacent to the operating level of the drilling rig; (iii) A pipe carrier supported by the base, having a first end and a second end, and configured to receive and support a portion of at least two connected pipes; (iv) A pipe carrier extension supported by the base, having a first end and a second end, the second end pivotally connected to the first end of the pipe carrier, the pipe carrier extension being pivotally movable about the second end between a folded position and an extended position, and when in the extended position, the pipe carrier extension being configured to receive and support another portion of the at least two connected pipes; and (v) A lifting member, supported by the base, pivotally connected to the pipe carrier at a first end and pivotally connected to the base at a second end by a foldable extension, and the lifting member being movable along the base towards and away from the second end of the elongated door.

5. The system according to claim 4, further comprising a pipe kicking system configured to move the at least two connected pipes between the connection system and the pipe handling device.

6. The system according to claim 4, further comprising a pipe storage tank system configured to convey individual pipe sections to and receive individual pipe sections from the connection system.

7. The system according to claim 4, wherein The connection system includes a make-up machine.

8. The system according to claim 7, wherein The make-up machine is configured to connect a first pipe and a second pipe to form at least two connected pipes, and wherein the make-up machine is further configured to release the at least two connected pipes in a direction substantially perpendicular to the longitudinal axis of the at least two connected pipes.

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