Threaded joint tongs with overload protection

Abstract

A device for manipulating threaded joints, the device including a set of tongs (32), a threaded rod (72), and a break-away member (96a) configured to fracture at a predetermined fracture load to prevent tension in the threaded rod beyond a predetermined tension limit. The set of tongs is formed by a first wrench (36) configured to engage a first member of a threaded joint and a second wrench (40) configured to engage a second member of the threaded joint. The first wrench includes a first lever arm (46) and the second wrench includes a second lever arm (48). The threaded rod is engaged with the first lever arm and the second lever arm to urge the first and second lever arms toward each other through tension in the threaded rod. The threaded rod is configured to maintain tension at the predetermined tension limit upon fracture of the break-away member.

Description

Attorney Docket No: 489825-0021-W001THREADED JOINT TONGS WITH OVERLOAD PROTECTIONBACKGROUND

[0001] This application claims priority to co-pending, prior-filed U.S. Provisional Patent Application No. 63 / 733,546, filed December 13, 2024, the entire contents of which is incorporated by reference herein.BACKGROUND

[0002] Horizontal directional drilling (HDD) systems include a series of drill rods joined end to end to form a drill string that is propelled though the ground by means of powerful hydraulic systems on a HDD machine, having the capacity to rotate while simultaneously pushing or pulling the drill string, as discussed in U.S. Patent 6,766,869 among numerous others. As an alternative to open trenching, HDD systems can enable utility lines for water, electricity, gas, telephone, cable television, fiber optics, and the like to be run underground for reasons of safety and aesthetics. The present disclosure relates to systems for making and breaking threaded joints such as those between two HDD drill rods. However, the devices and methods of the present disclosure may also apply to other types of threaded connections or joints. Within the field of HDD systems, for example, a drill string may utilize a threaded connection with a reamer (e.g., U.S. Patent 11,180,960) or a drill bit (e.g., U.S. Patent 11,105,156), or a drill head with electronics for steering - “sonde” (e.g., U.S. Publication 2024 / 0175347). The entire contents of each of the references mentioned above is incorporated by reference herein.

[0003] The present disclosure has application in the field of HDD systems, among other fields where threaded connections are made and / or broken, and overload protection is desirable.SUMMARY

[0004] In one aspect, the invention provides a device for manipulating threaded joints, the device including a set of tongs, a threaded rod, and a break-away member configured to fracture at a predetermined fracture load to prevent tension in the threaded rod beyond a predetermined tension limit. The set of tongs is formed by aAttorney Docket No: 489825-0021-US01 first wrench configured to engage a first member of a threaded j oint and a second wrench configured to engage a second member of the threaded joint. The first wrench includes a first lever arm and the second wrench includes a second lever arm. The threaded rod is engaged with the first lever arm and the second lever arm to urge the first and second lever arms toward each other through tension in the threaded rod.The threaded rod is configured to maintain tension at the predetermined tension limit upon fracture of the break-away member.

[0005] In another aspect, the invention provides a device for manipulating threaded joints, the device including a set of tongs formed by a first wrench configured to engage a first member of a threaded joint and a second wrench configured to engage a second member of the threaded joint, a threaded rod engaged with the first lever arm and the second lever arm to urge the first and second lever arms toward each other through tension in the threaded rod, and a torque limiter having a first configuration that allows an increase in tension in the threaded rod and a corresponding increase in torque applied to the threaded joint. The first wrench includes a first lever arm and the second wrench includes a second lever arm. The torque limiter has a second configuration that prevents an increase in tension in the threaded rod and prevents a corresponding increase in torque applied to the threaded joint. The torque limiter is configured to be triggered from the first configuration to the second configuration at a predetermined torque limit, without releasing the tension in the threaded rod.

[0006] In another aspect, the invention provides a method of manipulating a threaded joint, the method including providing a set of tongs formed by a first wrench and a second wrench, engaging a first member of threaded joint with the first wrench, engaging a second member of the threaded joint with the second wrench, tightening a nut onto the threaded rod to increase tension in the threaded rod, the tension urging the first and second lever arms toward each other to apply a torque to the first and second members of the threaded joint, and upon continued tightening of the nut, fracturing a break-away member at a predetermined fracture load to prevent tension in the threaded rod beyond a predetermined tension limit. The first wrench includes a first lever arm and the second wrench includes a second lever arm connected to theAttorney Docket No: 489825-0021-US01 first lever arm by a threaded rod. The threaded rod maintains tension at the predetermined tension limit upon fracture of the break-away member.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Fig. 1 is a side view of an operating horizontal directional drilling machine.

[0008] Fig. 2 is a first perspective view of a portable break-out device.

[0009] Fig. 3 is a second perspective view of the portable break-out device of Fig.2.

[0010] Fig. 4 is a first perspective cross-sectional view taken along line 4-4 in Fig. 2 of a first break-away member for use with the portable break-out device of Fig. 2.

[0011] Fig. 5 is a second perspective cross-sectional view taken along line 4-4 in Fig. 2 of an alternative break-away member for use with the portable break-out device of Fig. 2.

[0012] Fig. 6 is a perspective view of a portable break-out device, according to another implementation of the disclosure.DETAILED DESCRIPTION

[0013] Before any embodiments of the present invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following draw ings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

[0014] Fig. 1 shows an example of a drilling machine 10 in accordance with the present disclosure. The drilling machine 10 is adapted for pushing a drill string 14 into a surface 16 (e.g., a road surface, such as asphalt or concrete) in a first or downhole direction, and for pulling the drill string 14 from the surface 16 in a second or up-hole direction opposite the down-hole direction. The drill string 14 includes a plurality of drill rods (e.g., two of the drill rods 14a, 14b are shown and referred toAttorney Docket No: 489825-0021-US01 below) that are connected end-to-end by sequential couplings made on the drilling machine 10. A drill head 28 is generally mounted at a remote or down-hole end of the drill string 14 to facilitate driving the drill string 14 into the surface 16. The drill head 28 may include, for example, a cutting bit assembly, a starter rod, a fluid hammer, a sonde holder, as well as other components. Each of the drill rods 14a, 14b includes a mechanism for connection therebetween, such as threaded ends. A pin-end having external threads on one end of one rod 14a, for example, may be threaded into a boxend having internal threads on the adjacent rod 14b. The series of rods coupled in such a manner comprises the drill string 14. Accordingly, to couple an additional drill rod 14b with the remainder of the drill string 14, the additional rod may be rotated about longitudinal axis 26 and pushed toward the drill string 14 such that the external threads (pin end) on the additional drill rod 14b may be threaded with internal threads (box end) on the drill string 14. This is referred to as the make-up process.

[0015] The drilling machine 10 includes an elongated guide or track (e.g., rack) 22 that can be positioned by an operator at any number of different oblique angles relative to the surface 16. A carriage assembly 24 is slidably mounted on the rack 22. The carriage assembly 24 adapted for pushing a drill string 14 into a surface 16 (e.g., a road surface, such as asphalt or concrete) in a first or down-hole direction, and for pulling the drill string 14 from the surface 16 in a second or up-hole direction opposite the down-hole direction. The carriage assembly 24 is also adapted for rotating the drill string 14 in forward and reverse directions about a longitudinal axis 26 of the drill string 14. As used herein, the terms “forw ard direction"’ and “forward torque” refer to the direction of rotation of the drill string that tends to engage or tighten the threads of drill rods 14a and 14b. For example, if drill rods 14a and 14b have right-hand threads, the forward direction of rotation or torque is in a clockwise direction. The terms “reverse direction” and “reverse torque” refer to the direction of rotation of the drill string that tends to loosen or disengage the threads of drill rods 14a, 14b. Terms such as "upper” and “lower” may be used to describe the relative positions of machine components as well as the positions of the drill rods 14a, 14b used therewith. Because the machine 10 is configured to orient the rack 22 along a tilted or diagonal axis with respect to the ground (with well-established forward and rearward thrust directions of operation), the terms “upper” and “lower” are appropriate, as are "‘rearward” and “forward” or “up-hole” and “down-hole.” WithAttorney Docket No: 489825-0021-US01 particular reference to the up-hole drill rod 14b that gets removed by a break-out process, this may also be referred to as the withdrawn rod 14b since it has been retracted or withdrawn from the borehole, while the adjacent drill rod 14a in front of it may still be partially within the borehole.

[0016] More particularly, after the borehole has been drilled, it may be necessary to pull back the drill string 14 to remove the drill string 14 from the borehole. During the pull-back process, drill rods of the drill string 14 are individually withdrawn from the surface 16, uncoupled from the drill string 14, and returned to a drill rod storage structure. Often, back reaming is done as part of the pull-back process. To uncouple a withdrawn drill rod 14b from the remainder of the drill string 14, the threaded coupling between the withdrawn drill rod 14b and the adjacent drill rod 14a of the drill string 14 is required to be broken before the withdrawal drill 14b rod can be returned to the rod storage structure. This is referred to as the break-out process. Due to the torque loads associated with drilling and back reaming, threaded couplings between drill rods of a drill string can become quite tight and difficult to break.

[0017] During the break-out process, it may be desirable to utilize a portable device to perform the break-out process, rather than a built-in break-out mechanism. In this regard, a portable break-out device 32 may be used to perform the break-out process. The portable break-out device 32 may be further understood as a device for manipulating drill rods 14a, 14b or threaded joints. Additionally or alternately, the break-out device 32 may be used to install and / or remove a drill bit and / or a reamer, e.g., at an entrance to the borehole and / or the exit of a borehole.

[0018] As illustrated in Figs. 2-5, the portable break-out device 32 is a wrench assembly for connecting and / or disconnecting the withdrawn drill rod 14b and the adjacent drill rod 14a. The portable break-out device 32 includes a first clamp 36 configured to engage with the withdrawn drill rod 14b and a second clamp 40 configured to engage with the adjacent drill rod 14a. The first clamp 36 includes a set of hinged clamping jaws 42a. Similarly, the second clamp 40 includes a set of hinged clamping jaws 42b. Accordingly, the first clamp 36 and the second clamp 40 together form a set of tongs configured to non-rotatably grip, or engage, the drill string 14 to attempt decouple the withdrawn drill rod 14b from the adjacent drill rod 14a.Attorney Docket No: 489825-0021-US01

[0019] The portable breakout device 32 further includes a first lever arm 46 coupled with the first clamp 36 to form a first wrench 47 and a second lever arm 48 coupled with the second clamp 40 to form a second wrench 49. The first lever arm 46 includes a proximal end 52 and a distal end 56. The proximal end 52 of the first lever arm 46 is coupled with the first clamp 36. More particularly, the set of hinged clamping jaws 42a of the first clamp 36 is pivotally connected to the first lever arm 46. Similarly, the second lever arm 48 includes a proximal end 60 and a distal end 64. The proximal end 60 of the second lever arm 48 is coupled with the second clamp 40. More particularly, the set of hinged clamping jaws 42b of the second clamp 40 is pivotally connected to the second lever arm 48. Accordingly, the first lever arm 46 and the second lever arm 48 are configured as lever arms to tighten the first clamp 36 and the second clamp 40, respectively.

[0020] The portable break-out device 32 further includes a threaded rod 72 having a first end 76 and a second end 80. The distal end 56 of the first lever arm 46 is rotationally and pivotally coupled with the first end 76 of the threaded rod 72. More particularly, the distal end 56 of the first lever arm 46 is pivotally coupled with a first connecting block 90. The first connecting block 90 includes a first, or vertically extending (as shown in Figs. 2 and 3), aperture 69 configured to receive the first lever arm 46 such that the first lever arm 46 is pivotally coupled with the first connecting block 90. The first lever arm 46 may be retained from separating from the first connecting block 90 via, for example, a screw, or other corresponding fastener. In other words, the screw is configured to keep the first lever arm 46 and the first connecting block 90 assembled, while allowing for pivoting of the first lever arm 46. The first connecting block 90 further includes a second, or horizontally extending (as shown in Figs. 2 and 3), aperture 70 configured to receive the threaded rod 72 such that the threaded rod 72 is coupled with the first connecting block 90.

[0021] Similarly, the distal end 64 of the second lever arm 48 is rotationally and pivotally attached to the second end 80 of the threaded rod 72. More particularly, the distal end of the second lever arm 48 is pivotally coupled with a second connecting block 92. The second connecting block 92 includes a first, or vertically extending (as shown in Figs. 2 and 3), aperture 73 configured to receive the second lever arm 48 such that the second lever arm 48 is pivotally coupled with the second connectingAttorney Docket No: 489825-0021-US01 block 92. The second lever arm 48 may be retained from separating from the second connecting block 92 via, for example, a screw, or other corresponding fastener. In other words, the screw is configured to keep the second lever arm 48 and the second connecting block 92 assembled, while allowing for pivoting of the second lever arm 48. The second connecting block 92 further includes a second, or horizontally extending (as shown in Figs. 2 and 3), aperture 74 configured to receive the threaded rod 72 such that the threaded rod 72 is coupled with the second connecting block 92. Although the apertures 70, 74 in the respective connecting blocks 90, 92 can be provided as clearance holes, the threaded rod 72 extends between and operably couples the distal end 56 of the first lever arm 46 and the distal end 64 of the second lever arm 48 by way of the connecting blocks 90, 92. In other words, and in accordance with features described in further detail below, the threaded rod 72 extends between with the first lever arm 46 and the second lever arm 48 and is configured to urge the first and second lever arms 48 toward each other through tension in the threaded rod 72.

[0022] As illustrated in Fig. 3, the portable break-out device 32 further includes a plurality7of replaceable dies 68 positioned and configured for gripping the drill string 14. The plurality of replaceable dies 68 are substantially rectangular in shape and are configured to be received within the hinged clamping jaws 42a of the first clamp 36 and the second clamp 40, respectively, to accommodate a variety of sizes of threaded joint components, such as the wi th drawn drill rod 14b and the adjacent drill rod 14a. Accordingly, the plurality of replaceable dies 68 of various sizes can be interchanged to allow the portable break-out device 32 to be utilized on drill strings 14 of various diameters. More particularly, the portable break-out device 32 includes a first set of replaceable dies 68a configured to be received within the hinged clamping jaws 42a, 42b of the first clamp 36 and the second clamp 40 to accommodate a first size of the threaded joint. The portable break-out device 32 further includes a second set of replaceable dies 68b configured to be received within the hinged clamping jaws 42a, 42b of the first clamp 36 and the second clamp 40 to accommodate a second size of the threaded joint.

[0023] The threaded rod 72 is configured to apply and withstand tension at and beyond a predetermined tension limit, which corresponds to a maximum outputAttorney Docket No: 489825-0021-US01 torque that the set of tongs are configured to exert on drill string 14. In the present embodiment, the maximum output torque is approximately 11,500 foot-pounds. However, it should be noted that multiple versions of the break-out device 32 may exist that allow for various maximum torque outputs, for example, a smaller version of the break-out device may offer a maximum of torque output of 11,500 footpounds, and a larger version of the break-out device may offer a maximum torque output of 21,500 foot-pounds. Accordingly, in other embodiments, the predetermined maximum output torque may range from 5,000 to 25,000 foot-pounds.

[0024] The portable break-out device 32 further includes a first nut 84, or tightening element, fixedly secured to the first end 76 of the threaded rod 72. More particularly, the first nut 84 may be threadedly engaged and welded to the first end 76 of the threaded rod 72. In alternative embodiments, the first nut 84 may be fixedly secured to the threaded rod 72 via an adhesive or alternate fastening mechanism. The first nut 84 is configured such that torque can be applied to first nut 84 to turn the threaded rod 72 to increase the tension in the rod 72, and thereby, the output torque that the set of tongs exert on the threaded joint. Torque may be applied to the first nut 84 for tightening the threaded rod 72 by hand (i.e., manual operation of a wrench) or by an impact wrench. In other embodiments, other tools may be used to apply torque to the first nut 84. While the first nut 84 is described as a nut that forms a threaded engagement and is fixedly attached to the threaded rod 72 prior to being welded thereto, it should be understood that the threaded rod 72 and the first nut 84 may be replaced by a suitable component(s). For example, the threaded rod 72 may be provided as a bolt or machine screw having a head (e.g., hex head) in place of the welded-on nut 84. In either case, there is a torque input structure at the first end 76 configured to be engaged by a tool to turn the threaded rod 72.

[0025] The portable break-out device 32 further includes a second nut 88, or tension bearing element, threadedly engaged with the second end 80 of the threaded rod 72. More particularly, the second nut 88 is configured to maintain tension of the threaded rod 72 as tension is created in the threaded rod 72 through rotation of first nut 84 and threaded rod 72, thereby applying force to the first lever arm 46 and the second lever arm 48. The second nut 88 has a round outer profile (e.g., not a typical hex profile, and without “wrench flats”) that prevents a user from holding the secondAttorney Docket No: 489825-0021-US01 nut 88 with a wrench, for reasons that become apparent in view of the following description.

[0026] As described further below, the second nut 88 is coupled with the second connecting block 92 by a break-away member 96a (Fig. 4) such that the second nut 88 is rotatably fixed and can't rotate relative to the second connecting block 92. Preventing rotation of the second nut 88 allows the first nut 84 to increasingly tighten the threaded rod 72 into the second nut 88 up to the predetermined tension limit. Furthermore, the first nut 84 and the first connecting block 90 are configured such that tension in the threaded rod 72 is transferred to the first lever arm 46 and to the second lever arm 48 through the second nut 88 and the second connecting block 92, respectively. In other words, no tension is directly transferred between the threaded rod 72 and the first lever arm 46 and the second lever arm 48.

[0027] The break-away member 96a is a pin extending through cooperating apertures 89, 91 in the second nut 88 and the second connecting block 92, respectively. The break-away member 96a may be prevented from decoupling with the second connecting block 92 via a cap 94 and fastener 95. The fastener 95 may be a cotter pin, roll pin, or similar. In some embodiments, the fastener 95 may not be included. For example, the break-away member 96a may have a threaded (external) portion configured to engage a threaded (internal) portion on the second nut 88 and / or the second connecting block 92. In some embodiments, the cap 94 may be a thicker segment of the break-away member 96a that is thicker than a diameter of the cooperating apertures 89, 91 in the second nut 88 and the second connecting block 92. In yet other embodiments, the cap 94 may be a separate piece that is threaded onto an end of the break-away member 96a.

[0028] In the illustrated embodiment, the break-away member 96a is a shear pin. The shear pin 96a may be, for example, a solid pin of heat treated 4140 steel. As such, the break-away member 96a has a particularly high shear strength among commonly available materials. Accordingly, the break-away member 96a is not easily modified to increase the maximum torque that may be applied by the portable breakout device 32, as designed by the manufacturer. For example, a second or alternate break-aw ay member will either have the same strength or a reduced strength compared to the first or original break-away member 96a. This prevents the portableAttorney Docket No: 489825-0021-US01 break-out device 32 from exceeding the maximum output torque or a maximum desired torque of the threaded connection between the second nut 88 and the threaded rod 72 and undue over tensioning of the threaded rod 72, which could lead to failure of the threaded rod 72 or another part of the portable break-out device 32. It is also noted that the break-away member 96a has a consistent outer diameter along its length, particularly across the transition between the second nut 88 and the connecting block 92 (i.e., the break-away member 96a is not notched or preweakened). Although the above-noted features of the break-away member 96a provide certain features or advantages, it is explicitly noted that in other embodiments, the break-away member 96a may have other forms and may be made of alternate materials.

[0029] The break-away member 96a is configured to resist or prevent rotation of the second nut 88 up to the predetermined tension limit. In other words, the breakaway member 96a is configured to prevent rotation of the second nut 88 and allow the threaded rod 72 to be increasingly tightened by rotational force on the first nut 84 until the predetermined tension limit of the threaded rod 72 is reached. Additionally, the rotational torque on the first nut 84 creates a high enough tension in the threaded rod 72 such that, as rotation of the threaded rod 72 occurs, the rotation force of the threaded rod 72 causes the second nut 88 to overcome friction of the second nut 88 against the connecting block 92. The break-away member 96a is designed to break, or fail, at a predetermined fracture load that corresponds with the predetermined tension limit. Further, the predetermined tension limit corresponds to a torque applied by the operator on the first nut 84, which creates a shear force on the break-away member 96a such that the break-away member 96a fails due to shear forces. In other words, the break-away member 96a has a shearing strength equivalent to the maximum intended load of the portable break-out device 32. Accordingly, the break-away member 96a is configured as the weakest point of the portable break-out device 32 such that the break-away member 96a fails first when the predetermined tension limit is exceeded. When the break-away member 96a fails, the second nut 88 rotates with threaded rod 72 as any additional torque is applied to first nut 84. When the breakaway member 96a fails, the portable break-out device 32 is configured to maintain the tension on the rod until the second nut 88 is backed off or unthreaded. Accordingly, even if torque continues to be applied to the first end 76 of the threaded rod 72Attorney Docket No: 489825-0021-US01 following breakage of the break- away member 96a, the tension in the threaded rod 72 does not increase. Additionally, when the break-away member 96a fails, the second nut 88 is no longer rotationally coupled with the connecting block 92 meaning that the second nut 88 is no longer rotationally fixed and is no longer resisting rotation of the threaded rod 72. Accordingly, when the second nut 88 is no longer rotationally fixed, the first nut 84 cannot be tightened further because the second nut 88 rotates with the threaded rod 72.

[0030] To back off the second nut 88 from the threaded rod 72 after the breakaway member 96a fails due to the aforementioned shear forces, the second nut 88 must be rotationally fixed relative to the connecting block 92. The second nut 88 may be rotationally fixed relative to the connecting block 92 by inserting a new breakaway member 92a.

[0031] The break-away member 96a may further be understood as a torque limiter having a first, non-broken configuration, that allows an increase in tension in the threaded rod 72 and a corresponding increase in torque applied to the threaded rod 72. As such, the break-away member 96a may have a second, broken or failure, configuration that prevents an increase in tension in the threaded rod 72 and prevents a corresponding increase in torque applied to the threaded joint. As such, the breakaway member 96a is configured to be triggered from the first configuration to the second configuration at a predetermined torque limit, without releasing the tension in the threaded rod 72.

[0032] The break-away member 96a is configured to be the failure point for the portable break-out device 32 to allow for a retention and controlled release of stored energy if the portable break-out device 32 is torqued past the predetermined tension limit, instead of another component being the failure point. In other words, the breakaway member 96a is configured to prevent overloading of the portable break-out device 32. Furthermore, the break-away member 96a allows the intended failure point of the device to be a low cost and easily replaceable component. Additionally, implementing the break-away member 96a allows for the utilization of a power tool (e.g., an impact wrench, a drill, or any type of rotary impact tool) that is capable of higher torque loads and rotation speeds than a hand wrench to perform a faster breakout process. As such, the power tool used to apply rotation / torque can exceed theAttorney Docket No: 489825-0021-US01 torque required to cause failure of the break-away member 96a without introducing risk of breaking another part of the portable break-out device 32.

[0033] The break-away member 96a is removable and replaceable such that, in some embodiments, the break-away member 96a may be a first break-away member 96a configured to break, or fail, at the predetermined fracture load, which may be a first (or ultimate) predetermined fracture load. An alternative, second break-away member 96b may be configured to break, or fail, at a second predetermined fracture load that is less than the first predetermined fracture load. Accordingly, the second break-away member 96b may have a fracture load corresponding to a desired torque for coupling (make-up) of the threaded connection. The desired make-up torque provided by the second break-away member 96b is less than the ultimate torque for which the portable break-out device 32 is rated by the manufacturer.

[0034] While the following example refers to the drill rods 14a. 14b, it should be understood that the drill rods 14a, 14b are just one example of threaded joint components for use with the portable break-out device 32 during the break-out process. Accordingly, in operation, the break-out process begins with a user providing the set of tongs formed by the first clamp 36 and the second clamp 40. Next, the first clamp 36 is engaged with the withdrawn drill rod 14b and the second clamp 40 is engaged with the adjacent drill rod 14a. Next, the user applies a rotational force to the first nut 84 to rotate the threaded rod 72 into second nut 88 to increase tension in the threaded rod 72, the tension thereby urging the first and second lever arms 46, 48 toward each other and applying a torque to the withdrawn drill rod 14b and the adjacent drill rod 14a. The user may tighten the first nut 84 with a hand wrench or an impact wrench. In the event that the drill rod 14b and the adjacent drill rod 14a have not broken loose from their assembly torque when the predetermined tension limit has been reached, then upon continued tightening of the nut, the break-away member 96a fractures at the predetermined fracture load to prevent tension in the threaded rod 72 from increasing beyond the predetermined tension limit. Once the break-away member 96a has fractured, the threaded rod 72 maintains tension until the second nut 88 has been backed off of the threaded rod 72. To repeat the breakout process or back away second nut 88, the user may realign the apertures 89 and 91 and replace the break-away member 96a with another like break-away member 96a.Attorney Docket No: 489825-0021-US01

[0035] Fig. 6 illustrates a portable break-out device 132 according to another implementation of the disclosure. The portable break-out device 132 has the same material(s) and features of the portable break-out device 32 described above except where differences are specifically described below. As such, description of the portable break-out device 32 above applies equally to the portable break-out device 132 and, rather than duplicate description, reference is made to the description above. Like reference numerals plus ‘TOO” are employed with respect to Fig. 6 and should be understood to be supported by description of the like reference numerals described above, unless specifically described otherwise below.

[0036] The portable break-out device 132 includes a first lever arm 146 coupled with a first clamp 136 to form a first wrench 147 and a second lever arm 148 coupled with a second clamp 140 to form a second wrench 149. The first lever arm 146 includes a proximal end 152 and a distal end 156. The proximal end 152 of the first lever arm 146 is coupled with the first clamp 136. Similarly, the second lever arm 148 includes a proximal end 160 and a distal end 164. The proximal end 160 of the second lever arm 48 is coupled with the second clamp 140. The portable break-out device 32 further includes a threaded rod 172 having a first end 176 and a second end 180.

[0037] The distal end 156 of the first lever arm 146 is rotationally and pivotally coupled with the first end 176 of the threaded rod 172. More particularly, the distal end 156 of the first lever arm 146 is pivotally coupled with a first yoke 304 which is pivotally coupled with a first connecting block 190. Accordingly, the first yoke 304 includes a first, or vertically extending aperture 308 configured to receive the first lever arm 146 such that the first lever arm 146 is pivotally coupled with the first yoke 304. The first lever arm 146 may be retained from separating from the first yoke 304 via. for example, a screw, or other corresponding fastener. The first connecting block 190 includes a portion 316 received by the first yoke 304 such that the first yoke 304 can be pivotally coupled with the first connecting block 190. In other words, the first yoke 304 is substantially Y-shaped and is configured to be retained from separating from the first connecting block 190 via a pin 312 which extends through an aperture (not shown) in the portion 316 of the first connecting block 190. In other words, the pin 312 is configured to keep the first lever arm 146 and the first connecting blockAttorney Docket No: 489825-0021-US01190 assembled, while allowing for pivoting of the first yoke 304. The first aperture 308 of the first yoke 304 extends along an axis A which intersects the apertured portion 316 of the first connecting block 190 and a portion of the aperture 170 of the first connecting block 190 that receives the threaded rod 172. The first yoke 304 is configured to provide two-axis freedom of movement between the first lever arm 146 and the first connecting block 190. More particularly, in the present embodiment, the first lever arm 146 is configured to swivel relative to the first yoke 304. Additionally, the first connecting block 190 is configured to tilt, or pivot, (about the pin 312) with respect to the first yoke 304. In other embodiments, the first lever arm 146 may instead be configured to tilt and the first connecting block 190 may instead be configured to swivel.

[0038] Similarly, the distal end of the second lever arm 148 is pivotally coupled with a second yoke 320 which is pivotally coupled with a second connecting block 192. Accordingly, the second yoke 320 includes a first, or vertically extending, aperture 326 configured to receive the receive the second lever arm 148 such that the second lever arm 148 is pivotally coupled with the second yoke 320. The second lever arm 148 may be retained from separating from the second yoke 320 via, for example, a screw, or other corresponding fastener. The second connecting block 192 includes a portion 330 received by the second yoke 320 such that the second yoke 320 can be pivotally coupled with the second connecting block 192. In other words, the second yoke 320 is substantially Y-shaped and is configured to be retained from separating from the second connecting block 192 via a pin 324 extending through an aperture (not shown) in the portion 330 of the second connecting block 192. In other words, the pin 324 is configured to keep the second lever arm 148 and the second connecting block 192 assembled, while allowing for pivoting of the first yoke 304. The first aperture 326 of the second yoke 320 extends along an axis B which intersects the apertured portion 330 of the second connecting block 192 and a portion of the aperture 174 of the second connecting block 192 that receives the threaded rod 172. The second yoke 320 is configured to provide two-axis freedom of movement between the second lever arm 148 and the second connecting block 192. More particularly, in the present embodiment, the second lever arm 148 is configured to swivel relative to the second yoke 320. Additionally, the second connecting block 192 is configured to tilt, or pivot, (about the pin 324) with respect to the second yoke 320.Attorney Docket No: 489825-0021-US01In other embodiments, the second lever arm 148 may instead be configured to tilt and the second connecting block 192 may instead be configured to swivel.

[0039] As already noted, the particular configuration of the portable break-out device 32 may vary beyond those exact embodiments shown and described herein. The portable break-out device 32 may vary in quantity’, spacing, position, angle of attack, size and so forth without departing from the scope of certain aspects of the disclosure, such as those noted in the following claims.

[0040] Changes may be made in the above methods and systems without departing from the scope hereof. Also, aspects of various embodiments may be combined unless expressly prohibited. It should thus be noted that the matter contained in the above description or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense. The follow ing claims are intended to cover all generic and specific features described herein, as well as all statements of the scope of the present method and system, which, as a matter of language, might be said to fall therebetween.

Claims

Attorney Docket No: 489825-0021-US01CLAIMSWhat is claimed is:1 . A device for manipulating threaded joints, the device comprising: a set of tongs formed by a first wrench configured to engage a first member of a threaded joint and a second wrench configured to engage a second member of the threaded joint, wherein the first wrench includes a first lever arm and the second wrench includes a second lever arm; a threaded rod engaged with the first lever arm and the second lever arm to urge the first and second lever arms toward each other through tension in the threaded rod; and a break-away member configured to fracture at a predetermined fracture load to prevent tension in the threaded rod beyond a predetermined tension limit, wherein the threaded rod is configured to maintain tension at the predetermined tension limit upon fracture of the break-away member.

2. The device of claim 1, wherein the first wrench includes a set of hinged clamping jaws, one of which is pivotally connected to the first lever arm. and wherein the second wrench includes a set of hinged clamping jaws, one of which is pivotally connected to the second lever arm.

3. The device of claim 2, further comprising a first set of replaceable dies configured to be received within the hinged clamping jaws of the first wrench to accommodate a first size of the first member of the threaded joint, and a second set of replaceable dies configured to be received within the hinged clamping jaws of the first wrench to accommodate a second size of the first member of the threaded joint.

4. The device of claim 1, further comprising a first nut fixedly engaged with a first end of the threaded rod and a second nut threadedly engaged with a second end of the threaded rod, wherein the break-away member is configured to prevent rotation of the second nut and allow the first nut to increasingly tension the threaded rod up to the predetermined fracture load of the break-away member.Attorney Docket No: 489825-0021-US015. The device of claim 4, wherein the break-away member is a shear pin extending through cooperating apertures in the second nut and a connecting block that is pivotally connected to the second lever arm.

6. The device of claim 4, wherein the break-away member is a shear pin extending through cooperating apertures in the second nut and a connecting block that is pivotally connected to a yoke via a pin.

7. The device of claim 6, wherein the yoke is pivotally connected to the second lever arm.

8. The device of claim 5, wherein the shear pin is a solid pin of heat treated 4140 steel.

9. The device of claim 1, wherein the predetermined tension limit corresponds to a torque of 1 1.500 foot-pounds between the first wrench and the second wrench.

10. The device of claim 1 , wherein the predetermined tension limit corresponds to a torque of 21,500 foot-pounds between the first wrench and the second wrench.1 1. A system comprising: the device of claim 1 ; and at least one additional break-away member configured to replace the breakaway member and configured to fracture at a predetermined fracture load different than the predetermined fracture load of the break-away member.Attorney Docket No: 489825-0021-US0112. A device for manipulating threaded joints, the device comprising: a set of tongs formed by a first wrench configured to engage a first member of a threaded joint and a second wrench configured to engage a second member of the threaded joint, wherein the first wrench includes a first lever arm and the second wrench includes a second lever arm; a threaded rod engaged with the first lever arm and the second lever arm to urge the first and second lever arms toward each other through tension in the threaded rod; and a torque limiter having a first configuration that allows an increase in tension in the threaded rod and a corresponding increase in torque applied to the threaded joint, the torque limiter having a second configuration that prevents an increase in tension in the threaded rod and prevents a corresponding increase in torque applied to the threaded joint, wherein the torque limiter is configured to be triggered from the first configuration to the second configuration at a predetermined torque limit, without releasing the tension in the threaded rod.

13. The device of claim 12, further comprising a torque input structure at a first end of the threaded rod and a nut engaged with a second end of the threaded rod.

14. The device of claim 13, wherein the torque limiter member is configured to prevent rotation of the nut and allow increasing tension the threaded rod in response to torque applied at the torque input structure, up to the predetermined torque limit.

15. The device of claim 14, wherein the torque limiter is a shear pin extending through cooperating apertures in the nut and a connecting block that is pivotally connected to the second lever arm.

16. The device of claim 15, wherein the shear pin is a solid pin of heat treated 4140 steel.

17. The device of claim 15, further comprising:Attorney Docket No: 489825-0021-US01 at least one additional break-away member configured to replace the breakaway member and configured to fracture at a predetermined torque limit different than the predetermined torque limit of the break-away member.

18. The device of claim 13, wherein the torque input structure is a nut welded to the first end of the threaded rod.

19. The device of claim 12, wherein the torque limiter is fractured in the second configuration.

20. A method of manipulating a threaded joint, the method comprising: providing a set of tongs formed by a first wrench and a second wrench, wherein the first wrench includes a first lever arm and the second wrench includes a second lever arm connected to the first lever arm by a threaded rod; engaging a first member of a threaded joint with the first wrench; engaging a second member of the threaded joint with the second wrench; tightening a nut onto the threaded rod to increase tension in the threaded rod, the tension urging the first and second lever arms toward each other to apply a torque to the first and second members of the threaded joint; and upon continued tightening of the nut, fracturing a break-away member at a predetermined fracture load to prevent tension in the threaded rod beyond a predetermined tension limit, wherein the threaded rod maintains tension at the predetermined tension limit upon fracture of the break-away member.

21. The method of claim 20, wherein tightening the nut onto the threaded rod is performed by turning the threaded rod with an impact wrench.

22. The method of claim 20, further comprising: replacing the fractured break-away member with an additional break-away member.Attorney Docket No: 489825-0021-US0123. The method of claim 22, wherein the additional break-away member is configured to fracture at a predetermined fracture load different than the predetermined fracture load of the fractured break-away member.

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