Tower elevating catwalk system

Abstract

A tower elevating catwalk system and related methods. The tower elevating catwalk is configured to span a broader range of drill floor heights and presentation distances and / or angles to serve the various drilling rig designs.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of United States Provisional Patent Application Serial No. 63 / 758,231, filed February 13, 2025, which is herein incorporated by reference in its entirety.BACKGROUNDField

[0002] Aspects of the disclosure relate to catwalk systems configured to adapt to various rig geometries.Description of the Related Art

[0003] Catwalks are material handling systems used to pick up and lay down to and from ground (or a lower level) and a drill floor. Materials include but are not limited to drilling tubulars, tools, and equipment. Some catwalks have a fixed presentation height and distance capability. Other catwalks offer a limited range to adapt to different rig geometries. If a rig geometry falls outside of this limited range, the catwalk requires the addition, removal, replacing or modification of components to adapt to different drilling rigs but are still limited by design to cover the broader range of drill rig designs. It is often necessary to use another catwalk suited for the different rig geometry.

[0004] Therefore, there is a need for a catwalk system to span a broad range of drill floor heights and presentation distances or angles to serve the various drilling rig designs with the same catwalk system.SUMMARY

[0005] In one embodiment, a tower elevating catwalk system is configured to span a broad range of drill floor heights and presentation distances and / or angles to serve the various drilling rig designs. The tower elevating catwalk system may comprise a tower, a supporting link, one or more carriages, one or more locking links, and a trough. The tower elevating catwalk system is configurable to reach an infinitely adjustable presentation height and distance across a broad range.

[0006] In one embodiment, a tower elevating catwalk system comprises a chassis; a tower pivotably coupled to the chassis; a carriage coupled to the tower via a carriage slider pivot; a support link comprising a first end coupled to the carriage and a second end coupled to the tower via a support link slider pivot; a locking link coupled at one end to the carriage and coupled at an opposite end to the second end of the support link; and a trough coupled to the carriage.

[0007] In one embodiment, a method of operating a tower elevating catwalk system comprises moving a tower of the system from a lowered horizontal position to a raised vertical position; lifting a carriage of the system relative to the tower via a carriage slider pivot that is movable along a tower guide rail of the tower, wherein a trough is coupled to the carriage; and lifting a support link of the system relative to the tower via a support link slider pivot that is movable along the tower guide rail.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0009] FIG. 1 illustrates a tower elevating catwalk system in an extended position, according to one embodiment.

[0010] FIG. 2 illustrates the tower elevating catwalk system in a stowed position, according to one embodiment.

[0011] FIG. 3 illustrates the tower elevating catwalk system with a tower being erected into a vertical position, according to one embodiment.

[0012] FIG. 4 illustrates the tower elevating catwalk system with the tower in the vertical position and a slider pivot moved into a home position, according to one embodiment.

[0013] FIG. 5 illustrates the tower elevating catwalk system with a trough and a carriage being lifted, according to one embodiment.

[0014] FIG. 6 illustrates the tower elevating catwalk system with locking links in a locked position, according to one embodiment.

[0015] FIG. 7 illustrates the tower elevating catwalk system with continued lifting of the trough and the carriage, according to one embodiment.

[0016] FIG. 8 illustrates the tower elevating catwalk system in the extended position, according to one embodiment.

[0017] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one implementation may be beneficially utilized on other implementations without specific recitation.DETAILED DESCRIPTION

[0018] The disclosure contemplates that terms such as “couples,”“coupling,”“couple,” and “coupled” may include but are not limited to welding, interference fitting, and / or fastening such as by using bolts, threaded connections, pins, and / or screws. The disclosure contemplates that terms such as “couples,”“coupling,”“couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,”“coupling,”“couple,” and “coupled” may include but are not limited to direct coupling and / or indirect coupling, such as indirect coupling through components such as links.

[0019] Aspects of the disclosure relate to a tower elevating catwalk system and related methods.

[0020] According to one embodiment, a tower elevating catwalk system 100, as illustrated and described in FIGS. 1-8, is a free standing system that comprises a tower 101, support link 102, carriage(s) 103, 104, locking links 105, a trough 106, slider pivots (e.g. carriage slider pivots 107a, and support link slider pivots 107b), and a lifting system 110 to reach an infinitely adjustable presentation height and distance across a broad range. The optional locking links 105 may be adjusted for length to vary presentation angles, while the adding of carriage stages increase the presentation distance capability.

[0021] FIG. 1 illustrates a tower elevating catwalk system 100 in an extended position, according to one embodiment. The tower elevating catwalk system 100 comprises a tower 101 pivotably coupled (about pivot point 123) to a chassis 115 that is positioned on the ground. The chassis 115 may be in the form of a frame 116 and is the foundation structure of the system, which may also act as a skid for transport. The frame 116 has been partially omitted in FIGS. 2-8 for clarity.

[0022] The tower 101 may be a tower structure that is erected for operation. The tower 101 acts as a guide rail (and comprises a pair of tower guide rails 108) for the movable components of the tower elevating catwalk system 100 and the materials handled by the tower elevating catwalk system 100. As one example, the materials handled by the tower elevating catwalk system 100 may be tubulars such as drill pipe. The tower 101 is a fixed support structure during operation of the tower elevating catwalk system 100 and is lowered for stowing and catwalk system transport.

[0023] The tower 101 may be erected (e.g. raised to a vertical position and lowered to a horizontal position) via a tower erecting system 120, which may also be referred to as an actuator. The tower erecting system 120 is coupled to the tower 101 and the chassis 115. The tower erecting system 120 may be powered by various sources and / or systems, including but not limited to, hydraulic, electrical, pneumatic, mechanical, etc. The tower erecting system 120 can use, but is not limited to, cylinders or motors using gears, ropes, pulleys, chains, screws, or any other systems that can erect the tower 101 as needed. The tower erecting system 120 is illustrated in FIGS. 1-8 as comprising a cylinder 121 and a lift lug 122 (in the form of a cylinder rod). In an alternative embodiment, the tower can be externally handled and lifted to its erected position, such as by a crane or other external lift system.

[0024] The tower elevating catwalk system 100 further comprises a trough 106, which is the structure that supports the material being handled and delivered to and from a drill floor. The trough 106 may comprise a V-shaped profile to cradle tubulars and prevent them from rolling out during handling. However, the trough 106 can be of any shape or profile that allows staging and support of the materials being handled.

[0025] The tower elevating catwalk system 100 further comprises a lifting system 110, which may also be referred to as an actuator. The lifting system 110 is used to lift the trough 106 and one or more carriages 103, 104 that support the trough 106 relative to the tower 101. The lifting system 110 may be powered by various sources and / or systems, including but not limited to, hydraulic, electrical, pneumatic, mechanical, etc. The lifting system 110 can use, but is not limited to, cylinders or motors using gears, ropes, pulleys, chains, or any other systems that can lift the trough 106 and one or more carriages 103, 104 as needed. The lifting system 110 is illustrated in FIGS. 1-8 as comprising cylinders 111, lifting lug 114, ropes 112, and pulleys 113. The ropes 112 are coupled to the carriage slider pivots 107a to raise and lower the carriages 103, 104 upon actuation of the cylinders 111.

[0026] The tower elevating catwalk system 100 further comprises one or more carriages 103, 104. The carriages 103, 104 are the structures that are coupled to the tower 101 via the one or more translating slider pivots 107a, 107b. The carriages 103, 104 are supported by the lifting system 110 and the support link 102. The carriages 103, 104 also support the trough 106 directly or through a system of one or more intermediate carriages 104 if equipped. The carriages 103, 104 are illustrated in FIGS. 1-8 as comprising a main carriage 103 and an intermediate carriage 104. A trough / carriage extension system 130 may be used to extend the intermediate carriages 104, if equipped, and the trough 106. The trough / carriage extension system 130 is illustrated in FIG. 7 as comprising (but is not limited to) a rack, a pinion, a pulley 131, a rope 132, and a drum. In one embodiment, the trough / carriage extension system 130 may also be (such as a rack, pinion, pulley, rope, and drum) integrated with the slider pivots 107a, 107b and interact with a body supporting section 109 (such as a rack, pinion, pulley, rope, and drum) on the tower 101, which allows vertical motion to be converted into horizontal travel for the carriages 103, 104 or the trough 106.

[0027] The tower elevating catwalk system 100 further comprises the support link 102. The support link 102 is the structure that is coupled to the tower 101 via the one or more slider pivots 107b and supports the one or more carriages 103, 104. One end of the support link 102 may be coupled to the carriages 103, 104, and an opposite end of the support link 102 may be coupled to the tower 101 via the slider pivots 107b. One or more support links 102 may be used.

[0028] The tower elevating catwalk system 100 further comprises the one or more slider pivots 107a, 107b. The slider pivots 107a, 107b provide support of the main carriage 103 and the support link 102, and are guided and contained along a tower rail system, e.g. movable along the tower guide rails 108. The carriage slider pivots 107a are coupled to the main carriage 103 and to the lifting system 110. The slider pivots 107a, 107b can be, but are not limited to, any type of translating system, such as pads or rollers for example.

[0029] The tower elevating catwalk system 100 further comprises one or more locking links 105. The locking links 105 are collapsible links that further couple the main carriage 103 and support link 102 together. The locking links 105 may optionally be of adjustable length to control and vary presentation angle. The locking links 105 are collapsed or folded when in a stowed position. During operation, the locking links 105 unfold and engage the tower 101 at locking link guide rails 151. The locking link guide rails 151 are coupled to the tower guide rails 108 of the tower 101 and are configured to help secure the locking links 105 in a locked position.

[0030] The tower elevating catwalk system 100 further comprises a link collapsing system 140. As the lifting system 110 lowers the trough 106, the locking links 105 will be collapsed (e.g. released and / or folded) to allow the trough 106, the carriages 103, 104, and the support link 102 to lower to ground level at the chassis 115. The link collapsing system 140 may be actuated using hydraulic, electric, pneumatic, and / or mechanical power to collapse the locking links 105. The link collapsing system 140 is illustrated in FIGS. 1-8 as comprising a roller and cam 141. The link collapsing system, optionally, can be adjusted along with the lengths of the locking links 105.

[0031] FIGS. 2-8 illustrate a material pick-up operation. With reference to FIGS. 2-8, a drill floor height may be the distance from ground 201 to a first drill floor 202a or a second drill floor 202b. The distance may vary between drilling rig installations. A setback 203 may be the distance required between the tower elevating catwalk system 100 and the drilling rig structure 200 at the tower elevating catwalk system 100 level. This setback 203 distance may vary between drilling rig installations. A well center distance 204 may be the distance to well center (or rotary table) from the edge of the drilling rig structure 200. This well center distance 204 may vary between drilling rig installations and when added to the setback 203 determines a presentation (e.g. penetration) distance 207 of the tower elevating catwalk system 100. A presentation angle 205 may be the angle relative to ground 201 and the first drill floor 202a at which the tower elevating catwalk system 100 presents and delivers materials at the first drill floor 202a. A presentation height 206 may be the height from the second drill floor 202b at which the tower elevating catwalk system 100 presents and delivers materials.

[0032] FIG. 2 illustrates the tower elevating catwalk system 100 in a stowed position, according to one embodiment. When in the stowed position, the tower 101 is lowered, collapsed, stowed or removed. The tower elevating catwalk system 100 is not operational for material handling via the trough 106. The tower elevating catwalk system 100 is in mode for transporting, moving, and / or stowing.

[0033] FIG. 3 illustrates the tower elevating catwalk system 100 with the tower 101 being erected (e.g. raised), according to one embodiment. The tower 101 is erected into a vertical position. The tower 101 is erected by the tower erecting system 120 and / or an external lifting system, such as a crane. The slider pivots 107a, 107b are locked to the tower 101 (e.g. within the tower guide rails 108) and chassis 115, which helps control the movement of the carriages 103, 104 and the support link 102 along the tower 101 and the chassis 115 when the tower 101 is being erected. The movement of the carriages 103, 104 and the support link 102 allows the lifting system 110 to remain attached to the carriage 103, 104 via the carriage slider pivots 107a on the carriage 103, 104. The support link slider pivots 107b on the support link 102 are free to slide on the chassis 115 as necessary to allow the tower 101 to rotate about the pivot point 123 between the tower 101 and the chassis 115.

[0034] FIG. 4 illustrates the tower elevating catwalk system 100 with the tower 101 in the vertical position and the slider pivots 107a, 107b moved into a home position, according to one embodiment. The carriage slider pivot 107a connected to the carriage 103, 104 is unlocked and moved via the lifting system 110 to the home position. The support link slider pivot 107b, which is connected to the support link 102, is self-aligned to the tower rail system, which comprises the tower guide rails 108. One or more materials, such as tubulars, can be loaded onto the trough 106 at the chassis 115 level.

[0035] FIG. 5 illustrates the tower elevating catwalk system 100 with the trough 106 and carriages 103, 104 being lifted in the direction of reference arrow 150 by the lifting system 110, according to one embodiment. The lifting lug 114 (in the form of a cylinder rod) is retracted into the cylinder 111, which pulls the pulley 113 and ropes 112 downward in the direction of reference arrow 152, thereby lifting upward the carriage slider pivots 107a and thus the carriages 103, 104. The lifting system 110 raises the trough 106, the carriages 103, 104, the support link 102, and the locking links 105 along the tower 101 via the slider pivots 107a, 107b. The trough 106 and the carriages 103, 104 are lifted via the carriage slider pivot 107a. The support link 102 unfolds from the carriages 103, 104, and the locking links 105 unfold between the carriages 103, 104 and the support link 102.

[0036] FIG. 6 illustrates the tower elevating catwalk system 100 with the locking links 105 in a locked position about the roller and cam 141, according to one embodiment. The locking links 105 are movable along and lock into the locking link guide rails 151, and become a rigid support link. The carriages 103, 104, the support link 102, and the locking links 105 form a truss structure configured to support the load of the tower elevating catwalk system 100, including the materials supported on the trough 106, while being raised along the tower 101. Optionally, adjusting the length of the locking links 105 provides control and variability of the presentation angle 205 as required. Lengthening or shortening of the locking links 105 can be achieved by any means as required.

[0037] FIG. 7 illustrates the tower elevating catwalk system 100 with continued lifting of the trough 106 and the carriages 103, 104, according to one embodiment. The lifting system 110 lifts the trough 106, the carriages 103, 104, the support link 102, and the locking links 105. The trough / carriage extension system 130 can be used for extending the intermediate carriages 104, if equipped, and the trough 106 in the direction of reference arrow 153. The trough / carriage extension system 130 can be used to provide a greater presentation distance 207 by adding more telescoping carriages to the trough extension. Only one intermediate carriage 104 is shown in FIGS. 1-8. The trough / carriage extension system 130 may use vertical movement to power the extending of the intermediate carriage 104 and the trough 106 when engaged. For example, the trough / carriage extension system 130 illustrated in FIG. 7 comprises a rack, a gear, and a pulley system. The trough / carriage extension system 130 can be activated as a function of the lifting system 110 or powered by any one or more combination of actuators. Any means of adjusting, engaging, and timing of the trough / carriage extension system 130 can be used to control the lift path of the vertical travel and the horizontal travel of the material being handled in the trough 106.

[0038] FIG. 8 illustrates the tower elevating catwalk system 100 in the extended position, according to one embodiment. The lifting system 110 reaches its adjustable and predetermined height. The trough / carriage extension system 130 as illustrated in FIG. 7 extends (e.g. telescopes) the intermediate carriage 104 and the trough 106 to the adjustable and predetermined presentation distance 207 at the second drill floor 202b. The material can be offloaded from the trough 106 and conveyed to the second drill floor 202b.

[0039] The tower elevating catwalk system 100 can also be used to conduct a material lay-down operation. Material is loaded onto the trough 106 at the second drill floor 202b. Intermediate carriage(s) 104, if equipped, and the trough 106 are retracted or telescoped in and away from the second drill floor 202b. The lifting system 110 lowers the trough 106, the carriages 103, 104, the support link 102, and the locking links 105 along the tower 101 via the slider pivots 107a, 107b. Material is then unloaded at the chassis 115 level. Various other systems may be employed to stage, handle, and transfer materials onto, along, or out of the trough 106. Such systems may include (but are not limited to) skates, indexers, pipe racks, and / or kickers.

[0040] In one embodiment, a tower elevating catwalk system comprises a chassis, a tower pivotably coupled to the chassis, a carriage coupled to the tower via a carriage slider pivot, a support link comprising a first end coupled to the carriage and a second end coupled to the tower via a support link slider pivot, a locking link coupled at one end to the carriage and coupled at an opposite end to the second end of the support link, and a trough coupled to the carriage. The tower elevating catwalk system further comprises locking link guide rails coupled to the tower, wherein the locking link is movable along the locking link guide rails. The tower comprises tower guide rails, wherein the carriage slider pivot and the support link slider pivot are movable along the tower guide rails. The tower elevating catwalk system further comprises a tower erecting system configured to move the tower between a raised vertical position and a lowered horizontal position. The tower erecting system comprises a cylinder and a lift lug coupled to the chassis and the tower. The tower elevating catwalk system further comprises a lifting system configured to lift the trough and the carriage relative to the tower. The lifting system comprises a cylinder, a rope, and a pulley. The carriage comprises a main carriage and an intermediate carriage that is movable relative to the main carriage. The trough is coupled to the intermediate carriage. The locking link is a collapsible link.

[0041] In one embodiment, a method of operating a tower elevating catwalk system comprises moving a tower of the system from a lowered horizontal position to a raised vertical position, lifting a carriage of the system relative to the tower via a carriage slider pivot that is movable along a tower guide rail of the tower, wherein a trough is coupled to the carriage, and lifting a support link of the system relative to the tower via a support link slider pivot that is movable along the tower guide rail. A first end of the support link is coupled to the carriage, and a second end is coupled to the tower via the support link slider pivot. A locking link is coupled at one end to the carriage and coupled at an opposite end to the second end of the support link. The method further comprises moving the locking link along locking link guide rails that are coupled to the tower. The system further comprises a tower erecting system configured to move the tower between the raised vertical position and the lowered horizontal position. The tower erecting system comprises a cylinder and a lift lug coupled to the tower. The system further comprises a lifting system configured to lift the carriage relative to the tower. The lifting system comprises a cylinder, a rope, and a pulley. The carriage comprises a main carriage and an intermediate carriage that is movable relative to the main carriage. The trough is coupled to the intermediate carriage. The method further comprises positioning a tubular into the trough before lifting the carriage and the trough, and offloading the tubular from the carriage onto a drill floor after lifting the carriage and the trough to the drill floor. The method further comprises positioning another tubular from the drill floor into the trough, lowering the carriage and the trough relative to the tower, and offloading the tubular from the trough when lowered to the ground

[0042] It will be appreciated by those skilled in the art that the preceding embodiments are exemplary and not limiting. It is intended that all modifications, permutations, enhancements, equivalents, and improvements thereto that are apparent to those skilled in the art upon a reading of the specification and a study of the drawings are included within the scope of the disclosure. It is therefore intended that the following appended claims may include all such modifications, permutations, enhancements, equivalents, and improvements. The disclosure also contemplates that one or more aspects of the embodiments described herein may be substituted in for one or more of the other aspects described. The scope of the disclosure is determined by the claims that follow.

Claims

1. A tower elevating catwalk system, comprising:a chassis;a tower pivotably coupled to the chassis;a carriage coupled to the tower via a carriage slider pivot;a support link comprising a first end coupled to the carriage and a second end coupled to the tower via a support link slider pivot;a locking link coupled at one end to the carriage and coupled at an opposite end to the second end of the support link; anda trough coupled to the carriage.

2. The tower elevating catwalk system of claim 1, further comprising locking link guide rails coupled to the tower, wherein the locking link is movable along the locking link guide rails.

3. The tower elevating catwalk system of claim 1, wherein the tower comprises tower guide rails, wherein the carriage slider pivot and the support link slider pivot are movable along the tower guide rails.

4. The tower elevating catwalk system of claim 1, further comprising a tower erecting system configured to move the tower between a raised vertical position and a lowered horizontal position.

5. The tower elevating catwalk system of claim 4, wherein the tower erecting system comprises a cylinder and a lift lug coupled to the chassis and the tower.

6. The tower elevating catwalk system of claim 1, further comprising a lifting system configured to lift the trough and the carriage relative to the tower.

7. The tower elevating catwalk system of claim 6, wherein the lifting system comprises a cylinder, a rope, and a pulley.

8. The tower elevating catwalk system of claim 1, wherein the carriage comprises a main carriage and an intermediate carriage that is movable relative to the main carriage, wherein the trough is coupled to the intermediate carriage.

9. The tower elevating catwalk system of claim 1, wherein the locking link is a collapsible link.

10. A method of operating a tower elevating catwalk system, comprising:moving a tower of the system from a lowered horizontal position to a raised vertical position;lifting a carriage of the system relative to the tower via a carriage slider pivot that is movable along a tower guide rail of the tower, wherein a trough is coupled to the carriage; andlifting a support link of the system relative to the tower via a support link slider pivot that is movable along the tower guide rail.

11. The method of claim 10, wherein a first end of the support link is coupled to the carriage and a second end is coupled to the tower via the support link slider pivot.

12. The method of claim 11, further comprising a locking link coupled at one end to the carriage and coupled at an opposite end to the second end of the support link.

13. The method of claim 12, further comprising moving the locking link along locking link guide rails that are coupled to the tower.

14. The method of claim 10, wherein the system further comprises a tower erecting system configured to move the tower between the raised vertical position and the lowered horizontal position.

15. The method of claim 14, wherein the tower erecting system comprises a cylinder and a lift lug coupled to the tower.

16. The method of claim 10, wherein the system further comprises a lifting system configured to lift the carriage relative to the tower.

17. The method of claim 16, wherein the lifting system comprises a cylinder, a rope, and a pulley.

18. The method of claim 10, wherein the carriage comprises a main carriage and an intermediate carriage that is movable relative to the main carriage, wherein the trough is coupled to the intermediate carriage.

19. The method of claim 10, further comprising positioning a tubular into the trough before lifting the carriage and the trough, and offloading the tubular from the trough onto a drill floor after lifting the carriage and the trough to the drill floor.

20. The method of claim 19, further comprising positioning another tubular from the drill floor into the trough, lowering the carriage and the trough relative to the tower, and offloading the tubular from the trough when lowered to the ground.

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