EP2304166B1

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Info

Publication number: EP2304166B1
Application number: EP09740025.3A
Authority: EP
Inventors: Martin Liess; John D. Hooker; Reinhard Grosch; Thomas Kotschy; Andreas Carlsson
Original assignee: Weatherford Technology Holdings LLC
Current assignee: Weatherford Technology Holdings LLC
Priority date: 2008-05-02
Filing date: 2009-05-04
Publication date: 2019-10-09
Anticipated expiration: 2029-05-04
Also published as: EP3121367B1; WO2009135223A3; AU2009242439A8; EP3121367A3; CA2722544A1; AU2009242439A1; EP3121367A2; CA2722544C; AU2009242439B2; WO2009135223A2; EP2304166A2

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to methods and apparatus for handling tubulars using top drive systems. Particularly, the invention relates to methods and apparatus for adapting a top drive for use with running and rotating tubulars. More particularly still, the invention relates to a tubular handling apparatus for engaging with a tubular and rotating the same.

Description of the Related Art

It is known in the industry to use top drive systems to rotate a drill string to form a borehole. Top drive systems are equipped with a motor to provide torque for rotating the drilling string. The quill of the top drive is typically threadedly connected to an upper end of the drill pipe in order to transmit torque to the drill pipe. Top drives may also be used in a drilling with casing operation to rotate the casing.
In order to drill with casing, most existing top drives require a threaded crossover adapter to connect to the casing. This is because the quill of the top drives is not sized to connect with the threads of the casing. The crossover adapter is designed to alleviate this problem. Typically, one end of the crossover adapter is designed to connect with the quill, while the other end is designed to connect with the casing.
However, the process of connecting and disconnecting a casing is time consuming. For example, each time a new casing is added, the casing string must be disconnected from the crossover adapter. Thereafter, the crossover must be threaded into the new casing before the casing string may be run. Furthermore, this process also increases the likelihood of damage to the threads, thereby increasing the potential for downtime.
There is a need, therefore, for methods and apparatus for adapting the top drive for engaging and rotating a tubular such as casingWO-A2-2007/070805 andUS-A1-2008/059073 disclose tubular handling systems comprising a thread compensator.

SUMMARY OF THE INVENTION

The present invention generally relates to a method and apparatus for drilling with a top drive system. Particularly, the present invention relates to methods and apparatus for handling tubulars using a top drive system.
In accordance with one aspect of the present invention there is provided a thread compensator for use with a tubular gripping assembly, comprising an inner ring member rotatably coupled to an outer ring member and a cylinder for coupling the outer ring member to a non-rotating portion of the tubular gripping assembly, wherein the inner ring member is rotatable with a rotating portion of the tubular gripping assembly.
In accordance with another aspect of the present invention there is provided a tubular handling assembly comprising a gripping tool having a carrier movably coupled to a mandrel, wherein the carrier includes a gripping element; a link assembly coupled to the gripping tool; and a thread compensator. The thread compensator has an inner ring member rotatably coupled to an outer ring member and a cylinder for coupling the outer ring member to the link assembly, wherein the inner ring member is rotatable with the carrier.
In accordance with a further aspect of the present invention there is provided a method of handling a tubular. The method includes providing a gripping assembly having a carrier movably coupled to a mandrel, wherein the mandrel has a load collar adapted to couple to a shoulder of the carrier; a gripping element movable relative to the carrier; a thread compensator adapted to move the carrier; an engagement member movable relative to the carrier; and a stop member adapted to limit movement of the engagement member. The method includes lowering the gripping assembly until the engagement member contacts the tubular; lowering the carrier relative to the engagement member until the engagement member contacts the stop member; lowering the mandrel relative to the carrier such that a gap exists between the load collar and the shoulder; threadedly connecting the tubular to a second tubular; and actuate the thread compensator to move the carrier to compensate for threaded connection.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, 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 invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

Figure 1 shows an exemplary tubular handling apparatus adapted to engage an internal surface of the tubular.
Figures 2A and 2B shows an exemplary tubular handling apparatus adapted to engage an exterior surface of the tubular.
Figure 3 shows a cross-sectional view of a swivel and a link assembly attached to the internal gripping tool ofFigure 1.
Figures 4-6 are partial views of the link assembly shown inFigure 3.
Figure 7 is a partial cross-sectional view of the swivel shown inFigure 3.
Figure 8 is a partial cross-sectional view of the swivel and the mandrel shown inFigure 3.
Figures 8A-8E are additional views of the link assembly shown inFigures 1 and2.Figure 8A is a perspective view of the link support housing of the link assembly shown inFigure 1.Figures 8B-8D are partial cross-sectional views of the link support housing shown inFigure 8A.Figure 8E shows themandrel 110, theswivel 105, and thelink assembly 112, 113 prior to assembly to the mandrel of the external gripping tool shown inFigures 2A-2B.
Figure 9 is a cross-sectional of the link assembly ofFigure 1 attached to the mandrel. The link assembly is shown equipped with a turn counter.
Figure 10 shows an exemplary turn counter suitable for use with the link assembly shown inFigure 1.
Figures 10A-10D show another embodiment of a turn counter suitable for use with the link assembly shown inFigure1.
Figure 11 is a cross-sectional view of an exemplary internal gripping tool.
Figure 12 is a cross-sectional view of an exemplary hydraulic actuator suitable for use with the internal gripping tool shown inFigure 11.
Figure 13 shows a housing of the hydraulic actuator shown inFigure 12.
Figures 14-15 are partial views of an internal gripping tool ofFigure 1.
Figures 16-18 show sequential movement of the clamp indicator of the internal gripping tool ofFigure 1.
Figures 19A-19B show sequential movement of the coupling indicator of the internal gripping tool ofFigure 1.
Figure 20 is a perspective of an engagement plate of the internal gripping tool shown inFigure 1.
Figure 21 is a cross-sectional view of an exemplary external gripping tool.
Figure 22 is a cross-sectional view of an exemplary embodiment of a thread compensator.
Figures 23-25 show various positions of the carrier of the external gripping tool ofFigure 21.Figure 23 shows the position of the carrier during a pick up operation.Figure 24 shows the position of the carrier under normal operations.Figure 25 shows the position of the carrier when the external gripping tool is on the ground.
Figure 26 is a partial perspective view of the hydraulic actuator of the external gripping tool ofFigure 21.
Figure 27 is a partial cross-sectional view of the hydraulic actuator of the external gripping tool ofFigure 21.
Figures 28 and 28A show the coupling indicator and the clamping indicator in the released position.
Figures 29 and 29A show the coupling indicator in the tubular engaged position.
Figure 30 shows the gripping elements in the clamped position.
Figure 31 shows a perspective of a tubular guide member.
Figure 32 illustrates an exemplary gripping element suitable for use with the external gripping tool.
Figure 33 shows the guide pins of the gripping element ofFigure 32 positioned in thecarrier 250.
Figures 34A-34D illustrate an exemplary fill-up tool connection for connecting the fill-up tool to an external clamping tool.
Figures 35 and36 show an exemplary embodiment of a swivel.
Figure 37 show an embodiment of a thread compensator in the partially retracted position.
Figure 38 shows the thread compensator ofFigure 37 in the extended position.
Figure 39 shows a perspective view of the thread compensator ofFigure 37.
Figure 40 shows the thread compensator in the extended position.
Figure 41 shows the tubular positioned in the tubular gripping apparatus and gripped by the slips.
Figure 42 shows the carrier in a retracted position relative to the mandrel.
Figure 42A is an enlarged view of the thread compensator in a partially retracted position.Figure 42B is an enlarged view of the thread compensator in a fully retracted position.
Figure 43 shows the thread compensator in the drilling position.Figure 43A is a partial exploded view of the thread compensator in the drilling position.
Figure 44 shows a partial view of another embodiment of the tubular gripping apparatus equipped with a wedge lock release mechanism.
Figure 45 shows the position of the coupling indicator when the guiding element is contacting the rubber bumper.Figure 46 is a partial exploded view ofFigure 45.
Figures 47-50 are partial exploded views of the tubular gripping apparatus in operation.Figure 47 shows the tubular engaged with the bumper plate.
Figure 48 shows the carrier being lowered relative to the bumper plate.
Figure 49 shows the mandrel being moved relative to the carrier.
Figure 50 shows the mandrel in contact with the bumper plate.
Figure 51 shows an embodiment of a release mechanism in the unreleased position.
Figure 52 shows the release mechanism ofFigure 51 in the released position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Embodiments of the present invention provide a tubular handling apparatus for use with a top drive to engage and rotate a tubular such as casing.Figure 1 shows an exemplary tubular handling apparatus adapted to engage an internal surface of the tubular. The apparatus will be referred to herein as an internalgripping tool 100. The internalgripping tool 100 includesgripping elements 155 and anactuator 160 for actuating thegripping elements 155.Figures 2A and 2B shows an exemplary tubular handling apparatus adapted to engage an exterior surface of the tubular. The apparatus will be referred to herein as an externalgripping tool 200. The externalgripping tool 200 includes acarrier 250 for interacting with gripping elements and an actuator for actuating thegripping elements 260. The internalgripping tool 100 and the externalgripping tool 200 are equipped with aswivel 105 and alink assembly 108.
Figure 3 shows a cross-sectional view of theswivel 105 and thelink assembly 108 attached to themandrel 110 of the internalgripping tool 100. Themandrel 110 may be connected directly or indirectly to the quill disposed below the top drive. Thelink assembly 108 includeslinks 112 connected to alink support housing 113. In one embodiment, thelinks 112 may be extendable. Additionally, hydraulic actuation cylinders may be connected to thelinks 112 to tilt thelinks 112 to and away from a centerline of themandrel 110. Thelink support housing 113 has acentral opening 114 for receiving themandrel 110. Acoupling ring 116 disposed in theopening 114 is used to connect thelink assembly 108 to themandrel 110. Thecoupling ring 116 may be a nut which threadedly attaches to an exterior surface of themandrel 110. Thecoupling ring 116 is coupled to thelink support housing 113 using abearing connection 118, for example, a ball bearing. An exemplary ball bearing is a four point ball bearing having balls disposed between two rings and the balls are guided by two points on each ring. Thecoupling ring 116 is attached to one ring of the ball bearing, while thelink support housing 113 is attached to the other ring of the ball bearing. Thebearing connection 118 allows thecoupling ring 116 to rotate with themandrel 110 while thelink support housing 113 remains non-rotational. Also, thebearing connection 118 allows axial loads from thelinks 112 to be transferred to themandrel 110.
Figures 4-6 are different views of thecoupling ring 116 or nut. As shown, one or morearcuate clamping segments 121 may be disposed in an upper portion of thecoupling ring 116 and between the coupling ring and the mandrel. Thesegments 121 may be attached to thecoupling ring 116 using a fastener such as a bolt or screw. The clampingsegments 121 minimize the clearance and relative movement with thelinks 112 during rotation of thecoupling ring 116. One or moretapered ring segments 122 may also be disposed in a lower portion of thecoupling ring 116 to reduce radial clearance. In one embodiment, four clampingsegments 121 and two ring segments are coupled to thecoupling ring 116.Figure 5 is a partial view showing the clampingsegments 121 attached to thecoupling ring 116.Figure 6 a partial bottom view of the coupling ring 16 without themandrel 110. The view shows the threads of thecoupling ring 116 and the clampingsegments 121 andring segments 122.
Referring again toFigure 3, thelink assembly 108 may include aretainer 125 for connection to a torque reaction bracket ("TRB"). Theretainer 125 may be connected to an upper portion of thelink support housing 113 using fasteners such asbolts 124. In use, one end of the torque reaction bracket couples to theretainer 125 and another end couples to a rotationally fixed location, such as a rail on a drilling derrick or part of the top drive. This arrangement helps maintain thelink support housing 113 in a non-rotational position when themandrel 110 and thecoupling ring 116 are rotated by the top drive or motor.
In addition to thecoupling ring 116, thelink assembly 108 may also include a secondary retention device, such asshackles 126, for coupling with the top drive. In one embodiment, fourshackles 126 may be connected to the top portion of thelink support housing 113. An elongated member such as a rope, link, or chain may connect theshackles 126 to the link ears on the top drive. In this respect, thelink assembly 108 may be supported by the top drive.
Figures 7 and 8 are partial cross-sectional views of theswivel 105 and themandrel 110. The swivel includes anouter body 131, aninner body 132, and upper andlower bearings 133, 134 for relative rotational movement between theouter body 131 and theinner body 132. Theinner body 132 is connected to themandrel 110 using aspline connection 135 or other suitable mechanisms such as a pin connection. In this respect, theinner body 132 may rotate with themandrel 110. Theouter body 131 is coupled to thelink support housing 113 using atorque bolt 136. In this respect, theouter body 131 may remain stationary with thelink support housing 113 during rotation of themandrel 110 and theinner body 132. In this embodiment, theswivel 105 does not carry any axial load from thelinks 112. This axial load free arrangement allows other suitable swivel designs known to a person of ordinary skill in the art to be used with thelink assembly 108. The swivel may be used to supply fluid such as hydraulic fluid to the tubular handling apparatus for operation thereof. In another embodiment, the swivel may include one or more sensors for measuring the torque applied to the mandrel during its rotation.
Figures 8A-8E are additional views of the link assembly.Figure 8A is a perspective view of thelink support housing 113. In one embodiment, the link assembly may include amulticoupling 140 for connection to one or more control lines. Also, atorque counter 150 is attached to thelink support housing 113.Figures 8B-8D are partial cross-sectional views of the link support housing.Figure 8B is a cross-sectional view of thecoupling ring 116, thebearing 118, theretainer 125, and theturn counter 150.Figure 8C is a cross-sectional view of thelink support housing 113,coupling ring 116, thebearing 118, the clampingsegments 121, andring segments 122.Figure 8d is a cross-sectional view of thecoupling ring 116, thebearing 118, the clampingsegments 121, andring segments 122, theturn counter 150, and therotating plate 151.Figure 8E shows themandrel 110, theswivel 105, and thelink assembly 112, 113 prior to assembly to the mandrel of an external gripping tool. To assemble the tool, theswivel 105 is inserted over themandrel 110 and theinner body 132 is positioned into engagement with thespline 135. Thereafter, thelink support housing 113 inserted overmandrel 110 and threadedly attaches to the threads on themandrel 110 above theswivel 105. It must be noted that the swivel and/or the link assembly are usable with the internalgripping tool 100 or the externalgripping tool 200.
Figure 9 shows thelink assembly 108 equipped with aturn counter 150.Figure 10 shows an exemplary turn counter 150 usable with thelink assembly 108. Theturn counter 150 may include arotating plate 151 attached to thecoupling ring 116 and rotatable therewith. Theplate 151 has a plurality of teeth disposed on its outer perimeter. The turn counter 150 also includes one ormore sensors 152, 153 mounted to the non-rotational portion of thelink support housing 113. Thesensors 152, 153 are positioned adjacent the plurality of teeth and are adapted to detect the passing of each tooth. In one embodiment, thesensors 152, 153 detect the teeth using magnetic or inductive signals. Each sensor 152,153 is adapted to detect the presence or absence of the teeth. In an example of a plate having 250 teeth, each of the two sensors may generate a signal for the presence of the teeth and a signal for the absence of the teeth for a total combined 1,000 signals for each turn of the plate. Unlike prior known turn counters that use a gear for counting rotations, embodiments of the turn counter 150 directly measure the number of rotations of themandrel 110. The use of two signals allows the direction of the plate to be measured. However, it is contemplated that thelink assembly 108 may use one or more sensors to count the number of rotations of the plate or mandrel. In another embodiment, thesensors 152, 153 may be adjustable for proper positioning relative to theplate 151. For example, one or both of thesensors 152, 153 may be threadedly attached to theturn counter 150, and thus, rotated to adjust its position. Additionally, theturn counter 150 may be mounted to thelink support housing 113 using an adjustable mounting plate, which may be moved relative to therotating plate 151. In another embodiment, theturn counter 150 may be equipped with a gear for engaging therotating plate 151, whereby rotation of the gear may be used to calculate rotation of the tubular.
Figures 10A-10D show another embodiment of a turn counter suitable for use with thelink assembly 108 or other gripping tools.Figure 10A is a cross-sectional view of the turn counter along line A-A inFigure 10C. Figure 10B is a side view of the turn counter.Figure 10C top view of the turn counter.Figure 10D is a perspective view of the turn counter. The turn counter 50 may include a rotating plate attached to thecoupling ring 116 and rotatable therewith. The plate has a plurality of teeth disposed on its outer perimeter. The turn counter 50 includes anengagement gear 52 coupled to atransfer gear 53. Theengagement gear 52 is adapted to engage the teeth of the rotating plate. Rotation of theengagement gear 52 is transferred to thetransfer gear 53 which is coupled to acounting gear 55. Thecounting gear 55 shares the same rotational axis as thetransfer gear 53. In one embodiment, one or more sensors may be used to measure rotation of thecounting gear 55 to determine the number of rotations of the tubular. The turn counter 50 may include ahousing 51 to facilitate installation of the turn counter to the tubular handling apparatus.
The turn counter 150 also includes one ormore sensors 152, 153 mounted to the non-rotational portion of thelink support housing 113. Thesensors 152, 153 are positioned adjacent the plurality of teeth and are adapted to detect the passing of each tooth. In one embodiment, thesensors 152, 153 detect the teeth using magnetic or inductive signals. Each sensor 152,153 is adapted to detect the presence or absence of the teeth. In an example of a plate having 250 teeth, each of the two sensors may generate a signal for the presence of the teeth and a signal for the absence of the teeth for a total combined 1,000 signals for each turn of the plate. Unlike prior known turn counters that use a gear for counting rotations, embodiments of the turn counter 150 directly measure the number of rotations of themandrel 110. The use of two signals allows the direction of the plate to be measured. However, it is contemplated that thelink assembly 108 may use one or more sensors to count the number of rotations of the plate or mandrel. In another embodiment, thesensors 152, 153 may be adjustable for proper positioning relative to theplate 151. For example, one or both of thesensors 152, 153 may be threadedly attached to theturn counter 150, and thus, rotated to adjust its position. Additionally, theturn counter 150 may be mounted to thelink support housing 113 using an adjustable mounting plate, which may be moved relative to therotating plate 151. In another embodiment, theturn counter 150 may be equipped with a gear for engaging therotating plate 151, whereby rotation of the gear may be used to calculate rotation of the tubular.
Figure 11 is a cross-sectional view of an exemplary internalgripping tool 100. The internal gripping tool includes themandrel 110,gripping elements 155, and ahydraulic actuator 160 for actuating thegripping elements 155. As shown, thegripping elements 155 are wedge type slips disposed on a mating wedge surface of themandrel 110. Axial movement of the slips relative to themandrel 110 urges the slips to move radially outward or inward. The internalgripping tool 100 may optionally be equipped with a fill-uptool 158.
Figure 12 is an enlarged view of an exemplaryhydraulic actuator 160. Theactuator 160 includes ahousing 162 having a threadedconnection 166 to themandrel 110. Thehousing 162 may also be secured to themandrel 110 using aspline connection 161 or other suitable mechanisms such as a pin connection. One or moreactuator cylinders 164 attached to thehousing 162 usingbolts 163 are coupled to anactuator pipe 165. Theactuator pipe 165 is connected to thegripping elements 155. Activation of theactuator cylinder 164 urges axial movement of thegripping elements 155 relative to themandrel 110. A coupling engagement plate (or bumper plate 170) may also be attached to thehydraulic actuator 160. In one embodiment, theengagement plate 170 is movable relative to theactuator 160. Contact with the casing coupling may cause axial movement of theengagement plate 170. Astop member 178 may be provided to limit the travel of theengagement plate 170.
In one embodiment, thehydraulic actuator 160 may be removed from the internal gripping tool as one assembly. Referring toFigure 12, after removal of the swivel, thecrown nut 176 is removed. Theengagement plate 170 is then removed. Then, thebolts 163 to thehydraulic cylinder 164 are removed to disengage theactuator pipe 165 for removal. Theengagement plate 170 and theactuator pipe 165 are removed from the bottom of the internalgripping tool 100. The spline connection is then removed so that thehousing 162 may be unthreaded from themandrel 110.Figure 13 shows thehousing 162 after removal. It must be noted that one or more of these steps may be performed in any suitable order. For example, thebolts 163 may be removed before theengagement plate 170.
Figures 14-15 are partial views of an internal gripping tool provided with aclamp indicator 171 and acoupling indicator 172. In one embodiment, theclamp indicator 171 is an elongated member coupled to theactuator pipe 165 and movable therewith. Theclamp indicator 171 has tapered portions along its body to indicate the position of thegripping elements 155. As shown, theclamp indicator 171 has an upper portion, a middle narrow portion, and a lower portion. Asensor 175 positioned adjacent theclamp indicator 171 is adapted to send a signal indicating the position of thegripping elements 155. In one embodiment, thesensor 175 may include a sensor head attached to a piston. The piston may move the sensor head relative to the contour of theindicator 171, thereby determining the position of theindicator 171. For example, when the lower portion is detected, thesensor 175 would send a signal indicating that thegripping elements 155 are in the retracted, open position, as shown inFigure 14. As thegripping elements 155 are extended, the middle narrow portion is moved adjacent thesensor 175, which will indicate that thegripping elements 155 are clamped, as shown inFigure 15. As long as the middle portion is adjacent thesensor 175, thesensor 175 will continue to indicate that thegripping elements 155 are clamped.Figures 16-18 show the sequence of movement of theclamp indicator 171 relative to the sensor as thegripping elements 155 are extended. InFigure 16, the clampingindicator 171 shows the gripping elements are in the unclamped position. InFigure 17, the clamping indicator shows the gripping elements are in the clamped position as indicated by thesensor 175. InFigure 18, the upper portion is positioned adjacent thesensor 175, which indicates that thegripping elements 155 are clamped, but a tubular is not present.
Thecoupling indicator 172 may also be an elongated member having tapered portions to indicate the position of the tubular coupling. A lower end of thecoupling indicator 172 is connected to thecoupling engagement plate 170 and movable therewith. In one embodiment, thecoupling indicator 172 has an upper narrow portion and a lower wide portion to indicate the absence or presence of the coupling. Thesensor 175 for detectingclamp indicator 171 may be adapted to also detect thecoupling indicator 172. When the upper narrow portion is detected, thesensor 175 will signal that the coupling has not been contacted, as shown inFigure 19A. When the coupling engages theengagement plate 170 and causes theplate 170 to move, the lower wide portion will in turn be moved in position for detection by thesensor 175, which will signal that the coupling has been engaged, as shown inFigure 19B. In one embodiment, astop member 178 attached to theactuator housing 162 may limit the movement of theengagement plate 170. Additionally, thestop member 178 may be adapted to prevent or release a wedge lock situation. Embodiments of the wedge lock prevention are disclosed in a provisional patent application filed on the same date as the present application.Figure 20 is a perspective of theengagement plate 170 with respect to stopmember 178.
The signal from the coupling sensor may be used to prevent or allow movement of the gripping elements. For example, when thesensor 175 indicates the coupling has not contacted theengagement plate 170, the gripping elements may be prevented from actuation. In this respect, the gripping elements are prevented from gripping an improper location such as the coupling. In another example, when thesensor 175 indicates the coupling has contacted theengagement plate 170, the gripping elements will be allowed to grip the casing. In another embodiment, the signal from the clamping sensor may be used with an interlock system to ensure the tubular is not inadvertently released. For example, when the sensor indicates gripping elements are in the open position, the interlock system may prevent the spider from opening its slips. The interlock system will not allow the spider from opening until the clamping indicator sends a signal that the gripping elements have engaged the tubular.
Figure 21 is a cross-sectional view of the externalgripping tool 200. The externalgripping tool 200 includes amandrel 110 coupled to acarrier 250. Themandrel 110 has aload collar 211 which may engage an interior shoulder of thecarrier 250. Themandrel 110 may have a polygonal cross-section such as a square for transferring torque to thecarrier 250. The externalgripping tool 200 also includes a plurality ofgripping elements 255 and ahydraulic actuator 260 for actuating thegripping elements 255. In one embodiment, thehydraulic actuator 260 includes a plurality of pistons pivotally coupled to thegipping elements 255. One or more links may be used to couple thegripping elements 255 to the pistons. Thehydraulic actuator 260 may be attached to thecarrier 250 using a threaded connection. In one embodiment, thegripping elements 255 are slips disposed in thecarrier 250. Actuation of thehydraulic actuator 260 causes axial movement of the slips relative to thecarrier 250. Thegripping elements 255 have wedged shaped back surfaces that engage wedge shaped inner surfaces of thecarrier 250. In this respect, axial movement of thegripping elements 255 relative to the wedge surfaces of thecarrier 250 causes radial inward movement of the gripping elements. Thegripping elements 255 may be detached from theactuator 260 and removed through a window of thecarrier 250 or a lower end of thecarrier 250. The lower end of thecarrier 250 may include aguide cone 265 to facilitate insertion of the tubular. The externalgripping tool 200 may optionally be equipped with a fill-uptool 158. Embodiments of the fill-up tool suitable for use with the external gripping tool or internal gripping tool are disclosed inUS 2010-0032162. The fill-uptool 158 is attached to a lower end of themandrel 110 and is adapted to be inserted into the tubular. The fill-uptool 158 may include a valve for control fluid flow into or out of thetool 158.
Athread compensator 220 may be used to couple thecarrier 250 to themandrel 110. InFigure 22, the thread compensator is abiased thread compensator 220 that allows thecarrier 250 and its attachments to float independent of themandrel 110. In one embodiment, thecompensator 220 includes an attachment ring such as anut 221 threadedly attached to the exterior of themandrel 110 and abase plate 222 attached to themandrel 110. In this respect, thenut 221 and thebase plate 222 are fixed relative to themandrel 110. Acover 223 is provided above thebase plate 222 and around thenut 221 to support a plurality ofpins 224 that extend through apertures in thebase plate 222. Compression springs 225 are disposed around eachpin 224 and between thecover 223 and thebase plate 222. In this respect, thesprings 225 may exert a biasing force between thecover 223 and thebase plate 222. Alternatively, belleville washers may be used as the biasing member. Because thebase plate 222 is fixed to themandrel 110, thecover 223 is free to move up and down relative to thebase plate 222 as dictated by thespring 225. The movement of thecover 223 is also referred to herein as floating relative to thebase plate 222 ormandrel 110. The end of thepins 224 protruding from thebase plate 222 is connected to thecarrier housing 250. Thepins 224 may be connected to thecarrier 250 using a threaded connection. Thepins 224 allow thecarrier 250 to move with thecover 223, and therefore "float" in accordance with the biasing force applied by thesprings 225. In other embodiments, springs may be replaced by hydraulic cylinders.
Figures 23-25 show the position of thecarrier 250 relative to themandrel 110 at different steps during operation. Under normal operations as shown inFigure 24, thecarrier 250 is not supported by theload collar 211 of themandrel 110. It can be seen inFigure 24 that a gap exists between the load collar and thecarrier 250. Additionally, the weight of thecarrier 250 and its attachments is sufficient application a compressive force on thesprings 225, as illustrated by the gap betweenbase plate 222 and the top of thecarrier 250.Figure 23 shows thecarrier 250 during a pick up operation. During this operation, a lifting force is applied to themandrel 110 which overcomes the biasing force of thesprings 225. This allows themandrel 110 to move relative to thecarrier 250, thereby causing theload collar 211 to engage the shoulders of thecarrier 250. It can be seen inFigure 23 that the gap between theload collar 211 and thecarrier 250 has been eliminated.Figure 25 shows thecarrier 250 when the externalgripping tool 200 is on the ground. In this position, thesprings 225 have biased thecover 223 away from thebase plate 222 such that thecarrier 250 is contacting thebase plate 222. It can be seen inFigure 25 that the gap between theload collar 211 and thecarrier 250 has increased relative to the size of the gap under normal operations ofFigure 24.
The externalgripping tool 200 may also be equipped with aclamping indicator 271 and acoupling indicator 272.Figure 26 is a perspective view of theindicators 271, 272 and theirrespective sensors 274, 275 on the externalgripping tool 200.Figure 27 is a cross-sectional view of the externalgripping tool 200. Thecarrier 250 includes acoupling engagement plate 270 for engagement with the coupling of a tubular. Theengagement plate 270 includeskeys 276 that mate with theslots 277 in thecarrier 250. Thecoupling indicator 272 is coupled to theengagement plate 270 and is movable therewith. Thecoupling indicator 272 may be an elongated member having tapered portions to indicate the position of theengagement plate 270. In one embodiment, thecoupling indicator 272 has an upper narrow portion and lower wide portion to indicate the absence or presence of the coupling. Asensor 275 is provided to detect the position of thecoupling indicator 272. When the upper narrow portion is detected, thesensor 275 will signal that the coupling has not been contacted. When the coupling engages theengagement plate 270 and causes theplate 270 to move toward themandrel 110, the lower wide portion will in turn be moved in position for detection by thesensor 275, which will signal that the coupling has been engaged, as shown inFigure 29. As seen inFigure 29A, thebumper plate 270 has moved relative to theload collar 211.
Figures 28 and 28A show thecoupling indicator 272 and theclamping indicator 271 in the released position. With reference to theclamp indicator 271, in one embodiment, theclamp indicator 271 is an elongated member coupled to theleveling ring 278 of thehydraulic actuator 260 and movable therewith. The levelingring 278 is connected between the clamping cylinders and the gripping elements. The levelingring 278 may be used to ensure that thegripping elements 255 move in unison. Theclamp indicator 271 has tapered portions along its body to indicate the position of thegripping elements 255. As shown, theclamp indicator 271 has an upper wide portion and a lower narrow portion. Asecond sensor 274 positioned adjacent theclamp indicator 271 is adapted to send a signal indicating the position of thegripping elements 255. For example, from the release position shown inFigures 28 and 28A, thehydraulic actuator 260 may be activated to cause theleveling ring 278 and the gripping elements to move down. In turn, the upper wide portion is moved adjacent thesensor 275, which will indicate that thegripping elements 255 are clamped, as shown inFigure 30.
Figure 31 shows a perspective of atubular guide member 290 attached to a lower portion of the externalgripping tool 200. Thetubular guide member 290 may be used to facilitate insertion of the tubular into thecarrier 250. In one embodiment, thetubular guide member 290 is a cone shape guide member having one or more connection posts 291. Theposts 291 are adapted to engage with ananchor 292 on thecarrier 250. In one embodiment, pins 293 may be used to quickly attach or release theposts 291 from theanchors 292. Thetubular guide member 290 may optionally a set ofpins 294 for attachment of a smallersized guide member 290 to accommodate smaller tubular sizes.
Figure 32 illustrates an exemplarygripping element 255 suitable for use with the externalgripping tool 200. The upper portion of thegriping element 255 may have attachment members such as hooks or rings for coupling with thehydraulic actuator 260. The back surface of the gripping element may be wedge shaped for interacting with the wedge surface of thecarrier 250. The engagement surface of thegripping element 255 may be provided with a plurality of dies 295. In one embodiment, adie spacer 297 may be provided to separate the upper die from the lower die. Thedie spacer 297 may have an "L" shape and has a thickness that is greater than the upper die. The upper die rests on the horizontal portion to hold the die spacer in position. The back portion of thedie spacer 297 rests on the housing of thegripping element 255. In this respect, thedie spacers 297 may transfer load from the upper die to the housing.
Aguide pin 296 may be provided on the side wall of the housing to control the position of thegripping element 255 in thecarrier 250. Referring toFigure 33, the guide pins 296 may be disposed in grooves formed in the torque bars of thecarrier 250. The torque bars are positioned between adjacentgripping elements 255. The guide pins 296 prevent thegripping elements 255 from pivoting inward, thereby maximizing the opening in thecarrier 250 for receiving the tubular.
Figures 34A-34D illustrate an exemplary fill-up tool connection for connecting the fill-up tool to themandrel 110 of theexternal clamping tool 200. The fill-uptool mandrel 257 may havekeys 256 that provide a positive lock with a bore in thegripping tool mandrel 110. Additionally, aretention bolt 259 may be inserted radially through thegripping tool mandrel 110 and the fill-uptool mandrel 257.

SWIVEL

Figures 35 and36 show another embodiment of aswivel 305. Theswivel 305 is suitable for use with the tubular handling apparatus described herein and may replace theswivel 105 described with respect toFigures 7 and 8. Theswivel 305 may be operable between a casing mode and a drilling mode.Figures 35 shows theswivel 305 in the casing mode, andFigure 36 shows theswivel 305 in the drilling mode.
Theswivel 305 includes anouter body 331, aninner body 332, and upper andlower bearings 333, 334. Theinner body 332 may be connected to themandrel 110 using aspline connection 135. In this respect, theinner body 332 may rotate with themandrel 110. Alternatively, theinner body 332 may be connected to the mandrel using a pin connection. Theouter body 331 is coupled to the link support housing using a connector such as a torque bolt. In this respect, theouter body 331 may remain stationary with the link support housing during rotation of themandrel 110 and theinner body 332. In one embodiment, theswivel 305 may include one or more sensors for measuring the torque applied to the mandrel during its rotation.
Theswivel 305 includes aseal bushing 340 disposed between theouter body 331 and theinner body 332. Theseal bushing 340 includes one ormore ports 341, 342 in selective fluid communication with one ormore channels 351, 352 of theinner body 332. For example, afirst port 341 may be in fluid communication with afirst channel 351 to supply fluid to a connected tool such as the tubular handling apparatus, and asecond port 342 may be in fluid communication with asecond channel 352 to expel fluid from the tool.
Theseal bushing 340 is axially movable relative to theinner body 332.Figure 35 shows theseal bushing 340 in the lower position for operation in the casing mode.Figure 36 shows theseal bushing 340 in the upper position for operation in the drilling mode. In one embodiment, movement of theseal bushing 340 is hydraulically actuated. However, electric, mechanic, or pneumatic actuations of theseal bushing 340 are also contemplated. Theseal bushing 340 include afirst actuation channel 361 for supplying fluid out of the top of theseal bushing 340 to urge theseal bushing 340 to move downward. Theseal bushing 340 also includes asecond actuation channel 362 for supplying fluid out of the bottom of theseal bushing 340 to urge theseal bushing 340 to move upward. In another embodiment, theseal bushing 340 may be moved using a manual switch, a piston and cylinder assembly, or any suitable switching mechanism. The seal bushing may also be remotely controlled. In one embodiment, theseal bushing 340 may be locked into position. For example, a ball and detente assembly may be used to maintain theseal bushing 340 in position. An optional indicator may be used to indicate the position of theseal bushing 340. Exemplary indicators include a color marker or a pin. In one embodiment, seals may be positioned between an exterior surface of theseal bushing 340 and theouter body 331.
Theseal bushing 340 includes one ormore seals 365 disposed on an inside surface. The one ormore seals 365 engage or disengage from theinner body 332 depending on the position of theseal bushing 340. In one embodiment, theseal bushing 340 is in the casing (lower) mode when the inner body is at low rotational speeds or is stationary. In the casing mode, theseals 365 are engaged with an outside surface of theinner body 332 to prevent leakage of fluid at the interface between theport 341, 342 and thechannel 351, 352, as illustrated inFigure 35A. In this respect, fluid may be supplied to operate the tubular handling apparatus during casing mode. Theseal bushing 340 may be placed in the drilling (upper) mode during higher rotational speeds. In the drilling mode, theseals 365 are positioned adjacent a respective groove on an outer surface of theinner body 332, whereby theseals 365 do not contact theinner body 332, as illustrated inFigure 36A. In this respect, theseals 365 are disengaged from theinner body 332. When the seals are disengaged, theinner body 332 may rotate relative to theouter body 331 without contacting theseals 365, thereby prolonging the service life of theseals 365. During drilling, the tubular gripping apparatus typically remains in a gripped position such that fluid is not expected to be supplied fluid through theswivel 305 to operate the tubular gripping apparatus. In an alternative embodiment, the seals may be disposed oninner body 332 and the groove formed on theseal bushing 340. In one embodiment, a valve may be provided to ensure the fluid pressure of the tubular gripping apparatus in the gripped position in maintained. It must be noted that theswivel 305 may operate in the casing mode during drilling or higher rotational speed operations, even though the drilling mode is preferred at higher speeds to reduce wear on theseals 365. In one embodiment, the casing mode may be selected for operations at less than 50 rpm, and the drilling mode may be selected for operations at more than 50 rpm. In another embodiment, the mode of theswivel 305 may depend on the pending operation. For example, theswivel 305 may be in the casing mode during casing running operations and may switch to the drilling mode for drilling operations.
In another embodiment, movement of theseal bushing 340 may be linked to a controller. The controller may allow or prevent movement of theseal bushing 340 in response to certain conditions. In one embodiment, the controller may allow or prevent movement of theseal bushing 340 in response to the rotational speed of theinner body 332. For example, the controller may prevent theseal bushing 340 to move to the casing mode when the rotational speed is relatively high. In another example, the controller may allow theseal bushing 340 to move to the drilling mode when the rotational speed reaches a certain threshold level. In yet another example, the controller may prevent theseal bushing 340 from switching modes when there is pressure in the channels.
In operation, theswivel 305 may be used with tubular gripping apparatus for casing running and/or drilling operations. During casing running, theswivel 305 is operated in the casing mode such that fluid may be supplied through theports 341, 342 of theseal bushing 340 to operate the tubular gripping apparatus. The tubular gripping apparatus may be operated between an open or closed position to grip or release a tubular such as casing. Initially, the tubular gripping apparatus may grip a casing and place in alignment with a casing string in the spider. The casing is rotated into threaded connection with the casing string. The casing is rotated by transferring rotation from the top drive through theinner body 332 to the tubular gripping apparatus. Theswivel 305 may remain in the casing mode during rotation of the tubular gripping apparatus to connect the casing to the casing string. After connection, theswivel 305 may switch to the drilling mode in anticipation of the higher rotational speed. Theseal bushing 340 is moved relative to theinner body 332 to place theseals 365 adjacent thegrooves 368 of theinner body 332, whereby theseals 365 are disengaged. Thereafter, the tubular gripping apparatus may be rotated to urge the casing string into the formation. Theseal bushing 340 may switch back to the drilling mode when rotation is completed. In another embodiment, theseal bushing 340 may operated in the casing mode through the casing running and drilling process.

THREAD COMPENSATION

Figures 37-40 show another embodiment of athread compensator 520. Thethread compensator 520 is suitable for use with the tubular handling apparatus described herein and may replace thethread compensator 220 described with respect toFigure 22. The tubular handling apparatus includes amandrel 110 coupled to acarrier 250. Aswivel 305 such as the swivel shown inFigure 35 and36 disposed above the mandrel. Alink support housing 113 of alink assembly 108 such as the link assembly shown inFigure 3 is attached to themandrel 110 above theswivel 305. In another embodiment, the tubular handling apparatus may be provided with a torque measuring device. An exemplary torque sub is disclosed inUS 2007-0251701, with particular reference toFigures 6-6l and their respective description. The torque measuring device includes a torque shaft rotationally coupled to the top drive, a strain gage disposed on the torque shaft for measuring a torque exerted on the torque shaft by the top drive, and an antenna in communication with the strain gage. As shown inFigure 37, themandrel 110 may serve as the torque shaft for the torque measuring device. The strain gage may be at least partially disposed in the recessed diameter portion of themandrel 110. The torque measuring device may also include a turns counter for measuring rotation of the tubular and a stationary antenna in electromagnetic communication with the torque sub antenna. The turns counter and the stationary antenna may be located at a stationary position relative to the top drive. The torque measuring device may also include a computer is located at a stationary position relative to the top drive. The computer is in communication with the stationary antenna and the turns counter. The computer may be configured to monitor the torque and rotation measurements during rotation of the tubular; to determine acceptability of the threaded connection; and to stop rotation of the tubular when the threaded connection is complete or if the computer determines that the threaded connection is unacceptable.
Figure 37 show thethread compensator 520 in the partially retracted position, andFigure 38 shows thethread compensator 520 in the extended (or drilling) position. Thethread compensator 520 may be used to couple thecarrier 250 to themandrel 110. In one embodiment, thethread compensator 520 includes alift ring 525 connected to an upper portion of thecarrier 250. Thelift ring 525 may include aninner lift ring 525a coupled to anouter lift ring 525b. Theinner lift ring 525a includes atrack 535 defined by an upper ring plate and a lower ring plate. Theouter lift ring 525b includes one ormore rollers 530 disposed inside thelift ring 525 and movable in thetrack 535. A rotational axis of therollers 530 is directed along a radius of theinner lift ring 525a. Therollers 530 and thetrack 535 allow theinner lift ring 525a to rotate relative to theouter lift ring 525b. In one embodiment, theaxle 535 of theroller 530 may include a port for injecting lubricant to therollers 530, as illustrated inFigure 39.
Referring toFigure 38, theouter lift ring 525b is coupled to thelink support housing 113 of thelink assembly 108 using one ormore compensation cylinders 540. In this respect, thecompensation cylinders 540 do not rotate with thecarrier 250. In one embodiment, eachcompensation cylinder 540 includes acylinder housing 541 coupled to acylinder piston 542. Thecylinder housing 541 is connected to thelink support housing 113 and thecylinder piston 542 is connected to theouter lift ring 525b. In one embodiment, thecylinder housing 541 andcylinder piston 542 connections may be pivotal or fixed. Thecylinder 540 may be retracted to lift thelift ring 525 and thecarrier 250 and extended to lower thelift ring 525 and thecarrier 250. The pivotal connections allow thecylinder 540 to move in two dimensions relative to thelink support housing 113 to help reduce the bending stress on thecylinder 540 during operation, such as when the lift ring tilts. Thethread compensator 520 may include three, four, or any suitable number ofcylinders 540 to facilitate the movement of thecarrier 250. Thethread compensator 520 may be equipped with any suitable number ofrollers 530, such as six or eightrollers 530.
Thethread compensator 520 may optionally include one ormore torque bars 550 disposed between thelink support housing 113 and theouter lift ring 525b. The torque bars 550 may be adapted to retract or extend with thecompensation cylinders 540. The torque bars 550 may be disposed circumferentially on theouter lift ring 525b and between twocompensation cylinders 540. The torque bars 550 preferably do not use pivotal connections. In this respect, the torque bars 550 may limit the tilt thelift ring 525 may experience during movement. Also, the torque bars 550 may absorb reaction torque experienced by theouter lift ring 525b as a result of the rotation of theinner lift ring 525a. In another embodiment, thethread compensator 520 may optionally include compression springs to assist with maintaining the lift ring leveled.
Figures 40-43 shows thethread compensator 520 in various stages of thread compensation.Figure 40 shows thethread compensator 520 in the extended position and prior to receiving a tubular. In this position,carrier 250 is supported by theload collar 211 of themandrel 110. Theload collar 211 is at maximum separation distance from thebumper plate 170. The separation distance also represents the maximum stroke distance available for thread compensation.Figure 41 shows the tubular 501 positioned in the tubular gripping apparatus and gripped by the slips. The tubular is in contact with thebumper plate 170 of thecarrier 250. In this position, thecompensator 520 is ready to retract thecarrier 250 and the tubular in preparation for thread compensation.
Figure 42 shows thecarrier 250 in a retracted position relative to themandrel 110. Thecarrier 250 is retracted by retracting thecompensation cylinders 540 when the top drive is lowered toward the tubular 501. In this position, theload collar 211 is no longer supporting thecarrier 250. Instead, thecompensation cylinder 540 is now supporting thecarrier 250 and the gripped tubular. Thecarrier 250 may be retracted a distance that is sufficient to allow the threaded connection to be completed. For example, thecarrier 250 may be retracted for a distance that is at least equal to the length of the threaded connection. In one embodiment, thecarrier 250 is partially retracted such that a gap still exists between theload collar 211 and thebumper plate 170. The gap allows thecarrier 250 to move axially relative to themandrel 110 to release tubular, if necessary, thereby avoiding a wedge lock condition.Figure 42A is an exploded view of the thread compensator in a partially retracted position. It can be seen that theroller 530 is in contact with the upper portion of thetrack 535 such that thecompensation cylinder 540 may exert a lifting force on thecarrier 250 during tubular make-up. In one example, thecompensation cylinder 540 may retract the carrier 250 a distance of about 50% to 95% of the stroke distance; preferably, about 65% to 85%. For example, if the stroke distance for retraction is 8 inches (20 cm), then thecompensation cylinder 540 may retract the carrier 250 a distance of 6 inches (15 cm) in preparation for the thread compensation. Agap 560 of about 2 inches (5 cm) remains between thecollar 211 and thebumper plate 170. The retraction distance may be at least the length of the threads. If atorque bar 550 is used, thetorque bar 550 will retract with thecompensation cylinders 540.Figure 42B is an exploded view of thethread compensator 520 in a fully retracted position. As shown, theload collar 211 of themandrel 110 is in contact or close to contacting thebumper plate 170 in thecarrier 250.
Figure 43 shows thethread compensator 520 in the drilling position. In this position, the tubular thread connection has been completed. Thethread compensator 520 has returned to the fully extended position where thecarrier 250 is in contact with thecollar 211. In this respect, the weight of the connected tubular string is supported by thecollar 211. Also, torque from the top drive may be transferred to thecarrier 250 to rotate the tubular string for drilling operations.Figure 43A is a partial exploded view of thethread compensator 520 in the drilling position. In one embodiment, thecompensation cylinder 540 is adapted to position theroller 530 in location where theroller 530 does not contact the upper portion of theinner lift ring 525a. This separation prevents overheating between theroller 530 and theinner lift ring 525a during rotation of themandrel 110 and thecarrier 250 while drilling. It is contemplated that theroller 530 may contact theinner lift ring 525a during drilling operations.

WEDGE LOCK PREVENTION

Figure 44 shows a partial view of another embodiment of the tubular gripping apparatus equipped with a wedgelock release mechanism 620. The tubular gripping apparatus is shown with themandrel 610 supporting thecarrier 650. Thebumper plate 670 is positioned inside thecarrier 650 for engagement with the tubular. Engagement with the tubular may cause thebumper plate 670 to move axially relative to thecarrier 650. In one embodiment, thebumper plate 670 is coupled to thecarrier 650 using guidingelements 675 that are movable in aslot 655 of thecarrier 650.
Therelease mechanism 620 acts as a stop member for limiting the upward movement of the guidingelements 655 and thebumper plate 670. In one embodiment, therelease mechanism 620 includes ananchor 622 attached to thecarrier 650. Theanchor 622 may be attached using welding or other suitable methods of attachment. In another embodiment, theanchor 622 and thecarrier 650 may be formed from one piece of steel or other suitable material. Anengagement member 624 is coupled to theanchor 622 using aconnection device 626 such as a screw. Theengagement member 624 has a wedge surface that is movable along a wedge surface of theanchor 622. Movement of theengagement member 624 is controlled by releasing thescrew 626. Anoptional rubber bumper 628 releasably attached to theengagement member 624 may be provided for engagement with the guidingelement 675. Therubber bumper 628 may be exchanged as it wears down from use.
The tubular gripping apparatus may optionally include a coupling detection system for indicating presence of a coupling. The coupling detection system includes acoupling indicator 632 connected to the guiding elements. Thecoupling indicator 632 may be similar to thecoupling indicator 632 described with respect withFigures 15-17. Thecoupling indicator 632 may be an elongated member having tapered portions to indicate the position of the tubular coupling. A lower end of thecoupling indicator 632 is connected to thecoupling engagement plate 670 and movable therewith. In one embodiment, thecoupling indicator 632 has an upper narrow portion and a lower wide portion to indicate the absence or presence of the coupling. Asensor 635 may be adapted to read thecoupling indicator 632 to determine the presence or absence of the coupling in a similar manner as thesensor 175.Figure 45 shows the position of theindicator 632 when the guiding element is contacting therubber bumper 628.Figure 46 is a partial exploded view ofFigure 45.
Figures 47-50 are partial exploded views of the tubular gripping apparatus in operation. InFigure 47, the tubular gripping apparatus has been lowered until thebumper plate 670 engages thecasing 601. In one embodiment, the tubular gripping apparatus is lowered with thethread compensator 520 activated. In this respect, a substantial portion of the weight of the carrier is borne by thethread compensator 520, while the remainder is borne by the shoulder of themandrel 610. Thethread compensator 520 may hold at least 85% of the weight; preferably, at least 95%. As shown, thebumper plate 670 is at the lower end of theslot 655 and has not engaged therelease mechanism 620. In this position, further lowering of the apparatus will lower thecarrier 650 relative to thebumper plate 670, which is resting on top of thecasing 601.
Figure 48 shows the tubular gripping apparatus being lowered further. Thecarrier 650 has moved relative to thebumper plate 670, thereby causing the guidingelements 675 to engagerubber bumper 628 of therelease mechanism 620. In this position, further lowering of the apparatus will lower themandrel 610 relative to thecarrier 650. Also, a substantial portion of the weight of the carrier continues to be borne by thethread compensator 520, while the remainder is now borne by thebumper plate 670. Thethread compensator 520 may hold at least 85% of the weight; preferably, at least 95%. In addition, thecoupling indicator 632 has moved up with thebumper plate 670, which movement is detected by thesensor 635.
Figure 49 shows themandrel 610 relative to thecarrier 650 after the lowering of the tubular gripping apparatus has stopped and in anticipation of the thread compensation. As shown, themandrel 610 is not in contact with thebumper plate 670. The distance between the load shoulder of themandrel 610 and the shoulder of thecarrier 650 may be used for thread compensation. In one embodiment, a sensor may be provided to measure the optimal distance (i.e., the minimal distance required for thread compensation) has been reached. In another embodiment, a sensor may be provided to warn the distance is insufficient to avoid contact of themandrel 610 with thebumper plate 670.
Figure 50 shows the situation where themandrel 610 is contacting thebumper plate 670. This may occur after the casing has been made up and when a push force is applied to the casing string using the tubular gripping apparatus. This position allows axial force to be applied to the casing string without loading the gripping elements.
When the situation shown inFigure 50 occurs, thecarrier 650 cannot move upward to release the gripping elements. This situation may be referred as a "wedge lock" condition. To remedy this situation, thescrew 626 may be released from theanchor 622.Figure 51 shows thescrew 626 in the unreleased position.Figure 52 shows thescrew 626 in the released position. As thescrew 626 is released from theanchor 622, theengagement member 624 is moved along the wedge surface and away from the guidingelements 675, thereby creating a space 660 between therubber bumper 628 and guidingelements 675. The space 660 allows thecarrier 650 to move axially relative to the gripping elements, thereby releasing the gripping elements from the casing.
In addition to casing, aspects of the present invention are equally suited to handle tubulars such as drill pipe, tubing, and other types of tubulars known to a person of ordinary skill in the art. Moreover, the tubular handling operations contemplated herein may include connection and disconnection of tubulars as well as running in or pulling out tubulars from the well.
A is described for use with a top drive system. The swivel includes a mechanism to selectively engage and disengage the seals. When the seals are engaged, the swivel may transmit fluid between an inner body and an outer body. The seals are engaged during low rotational speed operations and disengage during high rotational speed operations. Disengagement of the seals during high speed rotations may extend the service life of the seals.
A thread compensator is described for use with a top drive system. The thread compensator is adapted to move the carrier relative to the mandrel of the tubular gripping apparatus. The thread compensator uses one or more extendable cylinders for axial movement of the carrier. One end of the cylinders may be attached to stationary portion of the tubular gripping apparatus and another end of the cylinder may be attached to a rotatable portion of the tubular gripping apparatus.
A wedge lock release mechanism is described for use with the tubular gripping apparatus. The release mechanism is operable to create a space between the mandrel and the bumper plate to facilitate the release of the gripping element.

Claims

A thread compensator (520) for use with a tubular gripping assembly,characterised by:
an inner lift ring (525a) rotatably coupled to an outer lift ring (525b); and
a compensation cylinder (540) for coupling the outer lift ring to a non-rotating portion of the tubular gripping assembly, wherein the inner lift ring is rotatable with a rotating portion of the tubular gripping assembly.
The thread compensator of claim 1, further comprising rollers (530) attached to the outer lift ring (525b), wherein the rollers are engageable with the inner lift ring (525a).
The thread compensator of claim 1 or 2, wherein extension or retraction of the compensation cylinder (540) compensates for axial movement of the tubular gripping assembly during makeup or breakout.
A tubular handling assembly, comprising:
a gripping tool having a carrier (250) movably coupled to a mandrel (110), wherein the carrier includes a gripping element (255);
a link assembly (108) coupled to the gripping tool; and
a thread compensator (220,520) having:
an inner lift ring (525a) rotatably coupled to an outer lift ring (525b); and
a compensation cylinder (540) for coupling the outer lift ring to the link assembly, wherein the inner lift ring is rotatable with the carrier.
The assembly of claim 4, further comprising a swivel (105); optionally,
wherein the swivel is coupled to the mandrel (110) at a location above the carrier; and optionally,
wherein the link assembly (108) is coupled to the mandrel at a location above the swivel.
The assembly of claim 4 or 5, further comprising a torque measuring device; and optionally,
a fill up tool connected to the mandrel (110).
The assembly of claim 4, 5 or 6, wherein the link assembly (108) includes a link support housing (113) rotatably connected to a coupling ring (116); optionally,
wherein the coupling ring is attached to the mandrel (110); optionally,
further comprising a swivel (105) having an inner body (132) attached to the mandrel (110) and an outer body (131) rotatable relative to the inner body; and optionally,
wherein the outer body is coupled to the link support housing.
The assembly of any of claims 4 to 7, further comprising a turn counter (150) having a turning member coupled to a rotating portion of the tubular handling assembly; and optionally, wherein the turn counter comprises a gear counter adapted to measure a rotation of the turning member.
The assembly of any of claims 4 to 8, further comprising:
a clamping indicator (271) coupled to the gripping element for indicating a position of the gripping element (255).
The assembly of any of claims 4 to 9, wherein the clamping indicator comprises a pin having at least two different widths.
The assembly of claim 10, further comprising a sensor (274) for determining a position of the clamping indicator.
The assembly of claim 11, wherein a signal from the sensor (274) is used to control movement of the gripping element.
The assembly of any of claims 4 to 12, further comprising a coupling indicator (272) coupled to a coupling engagement plate (270) of the gripping tool for indicating a position of the tubular.
A method of handling a tubular, comprising:
providing a gripping assembly having:
a carrier (250) movably coupled to a mandrel (110), wherein the mandrel has a load collar (211) adapted to couple to a shoulder of the carrier;
a gripping element (255) movable relative to the carrier;
a thread compensator (220,520) adapted to move the carrier;
an engagement member (170) movable relative to the carrier; and
a stop member (178) adapted to limit movement of the engagement member;
lowering the gripping assembly until the engagement member contacts the tubular;
lowering the carrier relative to the engagement member until the engagement member contacts the stop member;
lowering the mandrel relative to the carrier such that a gap exists between the load collar and the shoulder;
threadedly connecting the tubular to a second tubular; and
actuating the thread compensator to move the carrier to compensate for threaded connection.
The method of claim 14, wherein the engagement member (170) comprises a plate.