APPARATUS AND METHOD FOR HANDLING WELLBORE TUBULARS

Abstract

A handling apparatus and method for manipulation of tubulars include an elongate base such as a trailer supporting one or more layers of tubulars in a stack. A trough extends along the base for receiving and supporting a tubular and can be actuated to adjust its elevation such as to unstack or stack tubulars on the base, adjust its inclination to assist with longitudinal manipulation of the tubulars on and off of the trough. The trough can be oriented between an upright tubular supporting position and tipped transfer position for transfer of tubulars to and from an uppermost layer of the stack. More preferably, a pivoting grabber at the discharge end of the trough is used to engage and manipulate tubulars on and off of the trough.

Description

FIELD OF THE INVENTION

The invention relates to an apparatus and method for handling tubulars and in particular to an apparatus and method for transferring wellbore tubulars between a stack of wellbore tubulars on the apparatus and the work floor of an oil or gas well service rig.

BACKGROUND OF THE INVENTION

In the servicing of gas and oil wells, sectional wellbore tubulars such as drill pipe, collars and the like must be transferred to and from a well service rig. At the service rig, the tubulars are installed in or removed from the well, as necessary. Such tubulars are very heavy and service rig procedures require the tubulars to be raised or lowered approximately ten to twenty feet, thus requiring the use of mechanical aids for personnel to handle the tubulars for use and for stacking the tubulars for storage and transport. Some prior art tubular handling apparatus use slings and winches to raise and lower tubulars; however, these may be difficult to control, may not properly secure the tubular, and do not necessarily permit personnel to manipulate the tubular ends with the required precision and speed.

Alternatively, it is well known to utilize a trough for carrying tubular whereby the trough can be raised or lowered at a proximal end positioned adjacent a service rig to assist in transferring tubular to and from the rig floor, commonly referred to as “pick up” and “lay down”, respectively. In general, the trough is longitudinally positioned along a base and an elevation of the proximal end is adjusted by an actuator positioned between the base and the trough. The trough thereby moves between a lower horizontal position and an inclined position. Typically, a distal end of the trough, remote from the rig, is longitudinally movable along the base, such as by attachment of the trough to a roller or slide assembly in the base, to further adjust the position of the inclined trough toward the rig. When the trough is in the inclined position, a proximal end of a tubular received therein is generally positioned at the height of the rig floor. Workers on the rig can then attach the proximal end of the tubular to an elevator to pull the tubular off the trough for installation in the well. In the reverse operation, tubular that has been tripped out of the well is positioned on the inclined trough, which is then lowered to the base where the tubular can be unloaded and returned to storage racks or to a transport vehicle. Typically, cranes or other overhead lifting means are used for moving tubular between the pipe handler and other locations.

A variety of trough-base apparatus have been disclosed which have additional features to further assist in the mechanical handling of tubular. For example, U.S. Pat. No. 4,426,182 to Frias (“Frias”) provides a carriage or push member that is adapted to be driven bi-directionally between the ends of the trough for moving a tubular, such as pipe, up or down the inclined trough. Frias further discloses a discrete transferring assembly for transferring pipe between the trough and a storage rack. The transferring assembly is positioned on the side of the base and adjacent a rack located adjacent to the base. Pipe from the trough is rolled across the base to a tilt tray. The tilt tray tilts to receive pipe rolled over from the base and tilts to dump pipe to the rack or vice versa. Further, tilt tray is arranged as a four-bar linkage to adjust its height while remaining horizontal.

Canadian patent 2,224,638 to Morelli (“Morelli”) discloses a kicker nestably positioned within the trough for ejecting pipe out of the trough and onto the base. The kicker is operated by a rod that engages the underside of the kicker to laterally tip the kicker to roll the pipe out of the trough. A dump assembly is also provided to clear pipe from the base after it has been ejected from the trough. The dump assembly comprises a secondary trough nestably positioned in the base alongside the pipe trough. The secondary trough receives the ejected pipe and is moveable in an arc above the base to a point at which the pipe falls from the secondary trough and away from the base. Morelli also discloses a pivoting leg member that passively raises the end of the trough remote from the rig in response to longitudinal and vertical movement of the other end of the trough, to thereby permit further adjustment of the position of the inclined trough.

While Frias and Morelli generally reduce the manual labor required to use a trough-based handler, Frias has multiple discrete components and is complicated in design, while Morelli does not provide for transfer of tubulars between a stack and the trough. Further, prior art handling apparatus do not secure the ends of a tubular as it is being guided between the trough and the service rig, thereby risking injury to workers in the vicinity of the tubular. In addition, prior art pipe handling apparatus require that separate storage racks be provided for storing tubulars and separate transport vehicles be used for hauling pipe to and from the worksite.

Therefore, there is a need in the art for an improved apparatus for handling tubulars.

SUMMARY OF THE INVENTION

Applicant has provided an improved apparatus for handling tubulars that is simple in design and efficient in operation. The apparatus not only provides for transfer of tubulars to and from an elevated position, but also stacks and unstacks tubulars on the apparatus itself. Advantageously, the apparatus eliminates the need for a separate stacking rack, cranes and other equipment used for removing tubulars from the apparatus for storage and transport. In a preferred embodiment, the apparatus can be used both for transport of tubulars to the work site and for manipulation of tubulars for pick-up and lay-down operations. Further, the apparatus is capable of manipulating both ends of a tubular during tubular handling operations, thereby increasing versatility, increasing worker safety, minimizing components and reducing the requirement for manual handling of the tubular.

In one embodiment of the invention, stacking apparatus for handling tubulars on a base is provided comprising: a base for supporting a stack of one or more layers of a plurality of tubulars, the base preferably being a trailer; a trough having a longitudinal axis positioned along the base and having an open top for receiving a tubular; a first actuator for adjusting the elevation of the trough relative to the base and for at least maintaining the trough substantially parallel to the base; and a second actuator for orienting the open top of the trough between an upright supporting position and tipped transfer position for transfer of tubulars to and from an uppermost layer of the stack.

Preferably the first actuator is a trough control assembly comprising: a lift actuator for adjusting the elevation of a first distal end of the trough; an angle actuator connected between the base and the trough and spaced apart from the trough's distal end for adjusting the elevation of a second, proximal end of the trough wherein coordinated movement of the lift actuator and the angle control actuator permits elevation of the trough substantially parallel to the layers of tubulars, inclination of the trough through pivoting about the first and second pivots, or both elevation and inclination of the trough.

Further, longitudinal manipulation of tubulars is enhanced using a grabber spaced apart from the distal end of the trough, the grabber having a pivotal end connected to the base for pivotal movement of the grabber and having a grabber end for releasably grabbing a tubular supported in the trough and extending beyond the proximal end of the trough; and a third grabber actuator for pivoting the grabber towards and away from the distal end of the trough, whereby coordinated actuation of the trough control assembly and grabber actuators permits the grabber to manipulate tubulars longitudinally towards and away from the trough respectively through grabbing and pivoting of the grabber.

The apparatus enables a methodology for moving tubulars longitudinally to and from an off-base location such as a pick-up and lay-down operation in well servicing comprising: positioning the base with the proximal end of the trough adjacent the off-base location; unloading tubulars from the base comprising manipulating a tubular supported in the trough to the off-base location by elevating the proximal end of the trough with the tubular supported therein, pivoting the grabber end toward the trough to position the grabber end below the proximal end of the supported tubular, lowering the proximal end of the trough to engage the proximal end of the tubular with the grabber end, grabbing the tubular with the grabber end, and pivoting the grabber end away from the trough to manipulate the tubular longitudinally towards the adjacent off-base location, and releasing the tubular from the grabber end; and loading tubulars to the base comprising manipulating the tubular suspended at the off-base location to the trough by lowering the distal end of the tubular from the off-base location towards the base, grabbing the distal end of the tubular with the grabber end, guiding the distal end of the tubular with the grabber end to the trough, and pivoting the grabber end toward the trough to further guide the distal end of the tubular slidably and supportably into the trough.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are intended to illustrate embodiments of the invention and are not intended to limit the scope of the invention:

FIG. 1 is a perspective view of one embodiment of an apparatus of the present invention illustrated having a tubular loaded on the trough;

FIGS. 2a-c are side elevational views of the apparatus of FIG. 1 with the trough shown in a lower horizontal position (FIG. 2a), an upper horizontal position (FIG. 2b) and an inclined position (FIG. 2c);

FIGS. 2d-g are side elevational views of the apparatus of FIG. 1 shown having a tubular supported in the trough in an upper horizontal position (FIG. 2d); an inclined position (FIG. 2e); an inclined position (FIG. 2f) with a grabber arm positioned for engaging the tubular; and an inclined position with the grabber arm engaged with the tubular for longitudinal manipulation of the tubular (FIG. 2g);

FIG. 3a is a partial perspective view of the apparatus of FIG. 1 with a control box removed to view components of the lift actuator and tip actuator;

FIG. 3b is a proximal end view of the trough of FIG. 1 illustrating bi-lateral tipping movement of the trough, shown in dotted lines;

FIGS. 4a-4d are end views of a base and trough of the apparatus of FIG. 1 illustrating stacking of tubulars on the base, more particularly

FIG. 4a illustrates a tipping movement of the trough for stacking tubulars on the base;

FIG. 4b. illustrates a tipping movement of the trough for unstacking tubulars from the base and illustrates spacers positioned between layers of tubulars therein;

FIG. 4c illustrates a securing connection between the spacers and the base; and

FIG. 4d illustrates a lower spacer for use directly on the base;

FIGS. 5a-5c are schematic side elevational views of the apparatus of FIG. 1, showing manipulation of the trough between a horizontal elevated, a horizontal lowered and an inclined position respectively, and illustrating pivotal movement of the grabber arm and a grabber head (FIG. 5c);

FIGS. 6a and 6b are perspective views of an embodiment of the grabber head, the grabber head shown opened (released) and closed (grabbing or gripping) respectively;

FIGS. 7a and 7b are perspective views of another embodiment of the grabber head having roller bars, the grabber head shown opened and closed respectively;

FIGS. 8a-8g are schematic and side elevational views of the apparatus of FIG. 1 showing a sequence of operation for unloading pipe from the base to a service rig; and

FIGS. 9a-9e are side elevational views of the apparatus of FIG. 1 showing a sequence of operation for loading pipe from the service rig to the base.

DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIG. 1, an embodiment of an apparatus 20 for handling tubulars 21 comprises an elongated base 22 having a transfer or proximal end 24 for the loading and unloading of the tubulars to and from the base 22. For wellbore-related equipment, the proximal end 24 is generally positioned adjacent to a service rig (not shown). The base 22 extends longitudinally from the proximal end 24 to a distal end 26. When stored on the base 22, tubulars 21 are aligned longitudinally therealong. Tubulars 21 are transferred on and off of the base 22 through longitudinal and elevational manipulation of the tubulars 21. Elevational manipulation of a tubular 21 is provided in part using a longitudinally-extending, elevation and angle-variable trough 28. Longitudinal manipulation of the tubular is provided in part through a pivoting member or grabber 34 located adjacent the proximal end 24 of the base 22.

The trough 28 is generally V-shaped having an open top 29 for receiving and supporting a tubular 21 such as drill and production pipe. The trough 28 extends longitudinally along the base 22. A first actuator is provided for adjusting the elevation of the trough 28 relative to the base and for at least maintaining the trough substantially parallel to the base 22. The first actuator comprises a trough control assembly 32 generally positioned at the distal end 26 of the base 22 and connected to the trough 28 for assisting with elevational control of the trough 28. The first actuator further comprises an angle control actuator 50 positioned along the trough 28 for further assisting with elevational control of the trough 28.

Tubulars 21 are loaded and unloaded between a stack 30 (FIGS. 4a and 4b) of one or more layers of a plurality of tubulars 21 supported on the base 22.

The grabber 34 is positioned adjacent the proximal end 24 of the base 22 and is spaced apart from the trough 28. As described in more detail below, operation of the apparatus 20 requires coordinated repositioning of the elevation, the inclination, or both the elevation and inclination of the trough 28 by the trough control assembly 32 and the angle control actuator 50 and additionally with the grabber 34 for transferring a tubular 21 between the base 22 and an off-base location such as an elevated location including a gas or oil well service rig. A control box 36 houses control levers 38 for operating the apparatus 20 and is positioned at the distal end 26 of the base 22 to provide a convenient and safe location for manipulating tubulars 21 to and from the base 22 at the proximal end 24. Although the base 22 as illustrated is a mobile trailer, other varieties of a mobile or non-mobile base 22 can be used. It is to be understood that the term tubular(s) 21 includes any elongated member of circular cross-section or cylindrical member that is suitable for use with the apparatus 20.

Referring to FIGS. 2a-g, the trough 28 includes a first distal end 42 and an second and open proximal end 40, with the ends 42, 40 being adjacent the distal end 26 and proximal end 24 of the base 22, respectively. Both ends 42, 40 of the trough 28 are vertically moveable to elevate one or both ends of the trough 28 between a lowered horizontal position (FIG. 2a), a raised horizontal position (FIG. 2b), and an inclined position in which the proximal end 40 typically becomes elevated relative to the distal end 42 (FIG. 2c). As shown in FIGS. 2d-2g, a tubular 21 having proximal 44 and distal 46 ends is received within the trough 28. In one embodiment, so as to enable operation of the grabber 34 to engage a tubular 21 without interference with the trough 28, the trough 28 is longitudinally sized to be shorter than a tubular 21 supported thereon for enabling the proximal end 44 of the tubular 21 to project beyond the proximal end 40 of the trough 28 when the distal end 46 of the tubular 21 abuts the distal end 42 of the trough 28. The trough 28 can be elevated to receive the tubular 21 (FIG. 2d). The proximal end 40 of the trough 28 can be manipulated to incline the proximal end 44 of the tubular 21 (FIG. 2e) such as for engaging the grabber 34. The grabber 34 can be positioned to receive the tubular 21 (FIG. 2f) and the trough 28 lowered to engage the tubular 21 with the grabber 34 for longitudinal manipulation of the tubular 21 by the grabber 34. Referring also to FIG. 3a, to position or to prevent damage, such as to a threaded pin end of the distal end 46 of the tubular 21 when slid onto and along the open top 29 of the trough 28, a stop or bumper 41 made of rubber or other cushioning material can be positioned at the distal end 42 of the trough 28.

Referring to FIGS. 3a, 3b and FIGS. 4a, 4b, a second actuator or tip actuator 52 is provided for orienting and reorienting the open top 29 of the trough 28 between an upright supporting position and tipped transfer position for transfer of tubulars to and from an uppermost layer 100a of the stack 30. The trough 28 is rotationally moveable about its longitudinal axis for laterally tipping the open top 29 of trough 28 for loading or unloading tubulars 21 in one or either lateral direction or side. Preferably the trough 28 is positioned along about a midline of the base 22 and the trough 28 can be tipped to either side for forming a stack 30 on the base 22 on either side of the trough 28.

Trough Control Assembly

With further reference to FIG. 3a and FIGS. 5a-5c, movement of the trough 28 is controlled by the trough control assembly 32, which comprises a lift actuator 48 for adjusting the elevation of the distal end 42 of the trough 28, an angle control actuator 50 for adjusting the elevation of the proximal end 40 of the trough 28 including to adjust the angle of the trough 28, and the second tip actuator 52 for tipping the trough 28 to at least one side. The tip actuator 52 is supported by the lift actuator 48 at the distal end 42 of the trough 28 so that elevation of the distal end 42 of the trough 28 is independent of the operation of the tip actuator 52.

The lift actuator 48 is positioned adjacent to the distal end 42 of the trough 28 and comprises a trough tail-end guide plate 70 movable in a substantially vertical track 71. The trough 28 is supported by a support arm 74 which in turn is supported by the tail-end guide plate 70. The support arm 74 is rotationally actuable for rotation of the trough 28 about its distal end 42.

The lift actuator 48 comprises generally vertical lift member or arm 56 that is vertically actuated relative to the base 22 by a lift hydraulic cylinder 58 or other suitable actuator. In detail, a bottom end 60 of the lift hydraulic cylinder 58 is securely attached to the base 22, while a top end 62 of the lift hydraulic cylinder 58 is connected to a top end 64 of the lift arm 56 by a cross-connector 66. A bottom end 68 of the lift arm 56 is attached to, or is integrally formed with, the guide plate 70 that is slidably received between two opposing generally vertical side rails 71a,7b of the track 71 to permit vertical movement of the lift arm 56 while maintaining vertical alignment of the lift arm 56. Extending through the guide plate 70 is the T-shaped support arm 74. The T-shaped arm 74 is rotatable about a longitudinal axis to enable tipping of the trough 28 and is connected at the laterally extending T-intersection to a yoke 76 extending outwardly from the trough 28. The yoke 76 forms a first pivot 97 for pivotal connection at the T-intersection for enabling inclination of the trough 28 about its distal end 42. In this arrangement, extension and retraction of the lift hydraulic cylinder 58 causes the distal end 42 of the trough 28 to be raised and lowered at the guide plate 70, respectively, as seen in FIGS. 2a-c and FIGS. 5a-c.

Tipping Control

Referring also to FIGS. 3a and 3b, the tip actuator 52 comprises a crank arm 82 attached to the distal end 42 of the trough 28, with the crank arm 82 being actuated by a generally vertical tip hydraulic cylinder 84 or other suitable actuator. In detail, the crank arm 82 generally includes T-shaped arm 74 attached at one end 88 to the yoke 76 extending from the trough 28. The other end 90 of the T-shaped arm 74 is connected to a lever 92 that is further pivotally connected to the tip hydraulic cylinder 84. The T-shaped arm 74 of the lift actuator 48 is rotationally supported through a port 96 in the guide plate 70. The tip hydraulic cylinder 84 is connected between the lift arm 56 and the lever 92. As such, the tip actuator 52 is supported by and carried by the lift arm 56 as the lift arm 56 moves vertically. In use, extension and retraction of the tip hydraulic cylinder 84 causes rotational movement of the T-shaped arm 74 to tip the trough 28 from an upright position to the left and right. In addition, as best seen in FIG. 3b and also seen in FIGS. 5a-5c, a lateral pivot connection 99a is provided between the trough 28 and the angle control actuator 50 to permit tipping of the trough 28 by the tip actuator 52.

Angle Control

With reference to FIGS. 5a-5c, the angle control actuator 50 is connected to the trough 28 at a second pivot 99b positioned adjacent the proximal end 40 or intermediate the proximal and distal ends 40, 42 of the trough 28. The angle control actuator 50 is spaced away or apart from the lift actuator 48 for adjusting the elevation, the inclination or both the elevation and inclination of the proximal end 40 of the trough 28 through pivoting of the first and second pivots 97,99b. The angle control actuator 50 comprises any suitable actuator, which in one embodiment comprises an angle control hydraulic cylinder 78 pivotally connected between the base 22 and the second pivot 99b at the trough 28. As seen in FIGS. 2a-2c, extension and retraction of the angle control hydraulic cylinder 78 raises or lowers the proximal end 40 of the trough 28 relative to an elevation of the distal end 42 of the trough 28 as the distal end 42 is pivotally connected to the lift actuator 48. When the trough 28 is in the fully lowered position, as shown in FIG. 2a, the angle control hydraulic cylinder 78 is housed in the base 22 to lay flat under the trough 28. The second pivot 99b of the angle control hydraulic cylinder 78 to the trough 28 happens to be offset toward the proximal end 40 of the trough 28 relative to the pivotal connection to the base 22. This arrangement can be reversed.

Although the lift actuator 48 and angle control actuator 50, and the tip actuator 52 have been described with respect to the preferred embodiment, other suitable arrangements for adjusting the elevation and angle of the trough 28 while providing for tipping of the trough 28 can be employed, as would be contemplated by one skilled in the art.

Stacking

In operation and with reference to FIGS. 4a and 4b illustrating the stack 30, FIG. 3a illustrating the tipping of the trough 28, and FIGS. 5a and 5b illustrating the elevational manipulation of the trough 28, tubulars 21 can be stacked and unstacked on the base 22, with the stack 30 including one or more layers 100 of one or more tubulars 21. The apparatus 20 thereby eliminates the need for a separate tubular or pipe storage rack. Further, when the base 22 is a mobile base such as a trailer as shown in FIG. 1, the stack 30 can be hauled to and from a worksite without the need for a separate transport vehicle.

Generally, stacking and unstacking operations require coordinated adjustment of the elevation of the trough 28 using the lift actuator 48 and angle control actuator 50. Tubulars 21 are typically loaded laterally into and out of the trough 28 when the trough 28 is oriented substantially parallel to the base 22, tipping the trough 28 with the tip actuator 52, as necessary. Preferably, the grabber 34 is used to manipulate tubulars 21 longitudinally on and off of the trough 28, as described later in more detail.

Referring now to FIG. 4a, tubulars 21 supported in the trough 28 are stacked on the base 22 by adjusting the elevation of the trough 28 to correspond to an uppermost layer 100a of tubulars. The open top 29 of the trough 28 is then tipped to the side approximately ninety degrees to dump the tubulars 21 into the uppermost layer 100a of the stack 30. The loading, adjusting and tipping steps can repeated as desired to form a stack 30 of tubulars 21. Referring to FIG. 4b, to unstack tubulars 21 from the stack 30, the elevation of the trough 28 is adjusted at or slightly below the height of the uppermost layer 100a. Each tubular 21 is then rolled off the stack 30 and into the trough 28 for subsequent unloading longitudinally therefrom. Typically the open top 29 of the trough 28 is oriented upright prior to loading. The adjusting, rolling and unloading steps can be repeated as desired for unstacking. The layers 100 are separated by spacers which facilitate rolling of tubulars 21 within a layer 100. Preferably, the trough 28 is positioned longitudinally along a midline of the base 22 for stacking tubulars 21 on either side of the trough 28.

Alternatively (not shown), the trough 28 can be positioned along a side of the base 22 such that tipping of the open top 29 of the trough 28 is required to one side only. Positioned at the side of the base 22, the trough 28 can not only be used to stack tubulars 21 on one side of the base 22, but can also be used to stack tubulars 21 to a separate rack or other apparatus positioned adjacent an opposing side of the base 22.

To retain the stack 30 on the base 22, the plurality of tubulars 21 in a layer are constrained laterally. To prevent stacked layers of tubulars 21 from rolling toward the trough 28 and to provide a rolling surface for the tubulars 21 during stacking and unstacking operations, two or more of the spacers 104 can be removeably positioned between adjacent stacked layers 100,100 of tubulars 21. In particular, the spacers 104 comprise L-shaped bars having a downwardly depending retaining arm 108 adjacent the trough 28 so as to restrain tubulars 21 from rolling towards the trough 28. The spacers 104 are positioned to extend across each layer 100 transverse to the stack 30 and substantially perpendicular to the axes of the tubulars, with the retaining arm 108 adjacent the trough 28 and extending downwards toward a lower layer 100. The spacers 104 thereby provide a surface for rolling a tubular 21 of the plurality of tubulars within the layer 100 and between the layer and the trough 28. An opposing end 110 of the spacers 104 are removeably secured to the base 22.

Having reference to FIG. 4c, preferably, the securing connection is a collar 112 for engaging generally vertical side posts 114 which are securely attached to the base 22. In this arrangement, the side posts 114 also serve to prevent the tubulars 21 from rolling off the sides 116 of the base 22. During unstacking of tubulars 21, the collars 112 of the spacers 104 are removed from the posts 114 as each successive layer 100 is unstacked.

Preferably, as shown in FIG. 4d, a lower spacer 104a without a retaining arm 108, can be positioned under a lowermost pipe layer 100 to raise the tubulars 21 off the base 22 and permit tubulars 21 from the lowermost layer 100 to be rolled onto the trough 28 during unstacking. Alternatively, the trough 28 can be recessed within a trough cavity (not shown) in the base 22 such that the trough 28 is positioned slightly lower than the lowermost layer of pipe 100. When a lower spacer 104a is used, the lower spacer 104a can be integrally formed with a side post attachment member 118 for securing the side post 114 onto the base 22. In this arrangement, the weight of the tubulars 21 on the lower spacer 104a will add additional security for the attachment of the side posts 114 to the base 22.

Other configurations and arrangements for the retaining and spacing tubulars 21 on the base 22 can be used, as would be contemplated by one skilled in the art. For example, the spacer 104 can be an extended sheet rather than a bar, in which case only a single spacer may be necessary. Alternatively, the retaining pipe spacing functions may be provided as separate components, rather than as a unified component.

Loading and Unloading of Tubulars

Having described the stacking and unstacking operation of the apparatus 20, the apparatus 20 is now described with respect to moving tubulars 21 between the trough 28 and a destination adjacent the proximal end 24 of the base 22 such as the floor of a service rig. The stacking and unstacking are also generally referred to as “pick up” and “lay down”, respectively. In general, pick up and lay down operations require the coordinated movement of the proximal end 40 of the trough 28 by the angle control actuator 50, previously described, and the grabber 34.

Referring now to FIGS. 5a-5c, the grabber 34 is positioned at the proximal end 24 of the base 22 and spaced apart from the proximal end 40 of the trough 28. The grabber 34 comprises a grabber end 120 for releasably engaging or grabbing a tubular 21 and a pivot end 122 pivotally attached to the base 22 for enabling a pivoting movement of the grabber 34 towards (FIG. 5c, dotted lines) and away from the trough 28. In particular, the grabber end 120 comprises a grabber head 124, as described in more detail below, and the pivot end 122 comprises a grabber arm 126 to which the grabber head 124 is connected thereto.

The grabber arm 34 is pivotally moved by any suitable third actuating means which, in one embodiment, is a grabber arm hydraulic cylinder 128 that is pivotally connected to a midsection 130 of the grabber arm 126 and is further pivotally connected to the base 22. Extension and retraction of the grabber arm hydraulic cylinder 128 thereby pivotally moves the grabber arm 126 to move the grabber head 124 towards and away from the trough 28.

Preferably, the grabber arm 126 is further fit with a fourth actuator such as a hydraulic cylinder (not shown) for adjusting the elevation of the grabber head 124.

With reference to FIGS. 6a, 6b, 7a and 7b, the grabber head 124 generally comprises a lower jaw 132 connected to the grabber arm 126 and an upper jaw 134 pivotally connected to the lower jaw 132. A grabber head hydraulic cylinder 136 actuates the upper jaw 134 to pivotally move the upper jaw 134 toward and away from the lower jaw 132. The jaws 132,134 thereby releasably grab around a circumference of the tubular 21 positioned therebetween. The upper jaw 134 can securely grab a tubular 21 to lock relative movement therebetween for manipulation of the tubular 21 by the grabber 34, or the upper jaw 134 can also be adjusted to loosely fit around a tubular 21 to permit a guided or sliding of the tubulars 21 therethrough. Preferably, the lower jaw 132 is also pivotally connected to the grabber arm 126 to permit the angle of the grabber head 124 to conform to the orientation of the longitudinal axis of the tubular 21 supported therein.

In the preferred embodiment as shown in FIGS. 6a and 6b, the grabber head 124 comprises a generally U-shaped lower jaw 132, with the lower jaw 132 being sized to provide an enlarged area in which to catch a tubulars 21. In an alternative embodiment shown in FIGS. 7a and 7b, the lower jaw 132 comprises one or more roll bars 137, which guide and support a tubular 21 positioned thereon as described in more detail below.

The apparatus 20 is suitable for conducting operations to move tubulars longitudinally to and from an off-base location.

Referring now to FIGS. 8a-8g, pick up operations are illustrated which move tubulars 21, loaded one-by-one, onto the trough 28 and longitudinally onto the floor 140 of the off-base location such as a service rig 142. The proximal end 24 of the base 22, and thus the proximal end of the trough 40, is positioned adjacent the service rig 142. Preferably, the tubulars 21 are laterally loaded on the trough 28 from a stack 30 according to the unstacking operation of the apparatus 20 previously described. The side view schematic drawings of FIGS. 8a-8g do not illustrate the stack 30 for clarity of the operation of the trough 28 and a single manipulated tubular 21.

As shown in FIG. 8a, with the grabber 34 pivoted clear of the trough 28, the angle control actuator 50 inclines the trough 28 and elevating the proximal end 44 of the tubular 21 toward the floor 140 of the service rig 142, preferably with the distal end 42 of the trough 28 being in a fully lowered position. As shown in FIG. 8b, the grabber 34 is then pivoted toward the trough 28 to position the open grabber head 124 under the proximal end 44 of the tubular 21 which extends from the proximal end 40 of the trough 28. In this position, the open jaws 132,134 of the grabber head 124 form a U-shaped cradle for receiving the tubular 21. As shown in FIG. 8c, the proximal end 40 of the trough 28 is then lowered to engage the grabber head 124 which closes to grab the proximal end 44 of the tubular 21. The grabber 34 is pivoted away from the trough 28 to manipulate or pull the tubular 21 longitudinally toward the floor 140 of the service rig 142.

At FIG. 8d, personnel on the service rig 142 are then able to lower and engage a conventional elevator 143 to the proximal end 44 of the tubular 21 so as to enable lifting of the tubular 21 into the rig 142. The grabber head 124 is opened to the release the tubular as the elevator 143 begins to lift. At FIG. 8e and as the elevator 143 rises in the rig 142, the distal end 46 of the tubular 21 slides longitudinally along the trough 28 and eventually to lift the distal end 46 out of the trough 28.

If desired, either personnel or, more preferably, the grabber 34 can intercept the distal end 46 of the tubular 21 as it swings under gravity to approach the rig 142. Accordingly, as shown in FIG. 8e, the grabber 34 is pivoted toward the trough 28 and the distal end 46 of the tubular 21. The grabber head 124 is loosely positioned around the distal end 46 of the tubular 21 to guide the tubular 21 as it moves away form the trough 28. The grabber 34 is pivoted, at FIG. 8f, toward the rig 142 to help guide the distal end 46 of the tubular 21 as the elevator 143 continues to lift the tubular 21 being guided through the grabber end 124 and into the rig 142, until the tubular 21 is free of the trough 28 (FIG. 8g) and is fully supported in the rig 142.

Referring now to FIGS. 9a-9g, after a tubular 21 has been tripped out of a well, the top or proximal end 44 of the tubular 21 is suspended from the elevator 143 in preparation for laying down of a tubular 21 onto the trough 28, with the proximal end 24 of the base 22 positioned adjacent the service rig 142. At FIG. 9b, with the grabber 34 pivoted toward the rig 142, the elevator 143 is lowered and the tubular 21 is slid downwards towards the base 22 guided the lower jaw 132 of the open grabber head 124 and the grabber 34 is manipulated or pivoted towards the trough 28 to position the bottom or distal end 46 of the tubular 21 thereon after which the grabber 34 is released and pivoted out of the way. As shown in FIG. 9e, the grabber 34 is then pivoted toward the rig 142. The tubular 21 is lowered to the grabbing head 124 so as to support and guide the proximal end 44 of the tubular when the tubular 21 is released from the elevator 143. The grabber head 124 is closed to grab the tubular 21. In FIG. 9f, the grabber 34 is pivoted toward the trough 28 to further slide the tubular 21 along the trough 28 such as until the tubular 21 abuts the distal end 42 of the trough 28. As shown in FIG. 9g, the proximal end 40 of the trough 28 is then raised to support the tubular 21 thereon and to enable release of the grabber 34. The grabber head 124 is opened to release from the tubular 21 and is moved away from the trough 28. Thereafter, the trough 28 is adjusted and the tubular 21 is stacked, completing the operation. Referring back to FIG. 4b, the trough 28 is manipulated parallel with the uppermost layer 100a in the stack. The tubular 21 can then be unloaded from the trough 28 as previously described.

During the tubular handling operations described in FIGS. 8a-9g, a length of the grabber arm 126 and an angle of the grabber head 124 may also be adjusted, as required, to permit the grabber 34 to grab the tubulars 21 and otherwise manipulate the ends of the tubulars 21.

While it is preferable that the pick up and lay down operations of the apparatus 20 be performed in conjunction with the unstacking and stacking operations, respectively, this is not required. For example, the grabber 24 can be used with a trough 28 in which only the proximal end 40 of the trough 28 can be lifted. In this case, other means must be used to stack and unstack tubulars such as pipe. In another example using the stacking embodiment, a carriage member rather than the grabber 34 may be implemented for longitudinally moving tubulars 21 along the trough 28.

While the preferred embodiment has described the use of the apparatus 20 for handling wellbore tubulars 21 and in the context of a service rig 142, the apparatus 20 can be used in any situation that requires stacking and unstacking or picking up and laying down of tubulars 21. For example, the apparatus 20 can be used at a construction site for handling rebar or pilings, and which are further handled by an elevator such as a crane.

The base 22 incorporates additional safety and environmental features such as deck drip trays or catch basins which correspond to the distal and proximal ends 46,44 of the tubulars 21 for receiving fluids draining therefrom and minimizing spills. An operator control platform for manipulation of the trough 28 and grabber 34 is located remote from the tubulars 21 themselves. Load stabilizers are provided to secure the base 22 when incorporated in a wheeled trailer. Personnel safety is improved through minimization of worker contact with heavy tubulars 21 in motion through mechanization of tubular 21 manipulation.

Although preferred embodiments of the invention have been described in some detail herein above, those skilled in the art will recognize that various substitutions and modifications of the invention may be made, without departing from the scope of the invention.

Claims

1. An apparatus for handling tubulars comprising:

a base for supporting a stack of one or more layers of a plurality of tubulars;

a trough having a longitudinal axis positioned along the base and having an open top for receiving a tubular;

a first actuator for adjusting the elevation of the trough relative to the base and for at least maintaining the trough substantially parallel to the base; and

a second actuator for orienting the open top of the trough between an upright supporting position and tipped transfer position for transfer of tubulars to and from an uppermost layer of the stack.

2. The apparatus of claim 1 wherein the first actuator is a trough control assembly comprising:

a lift actuator for adjusting the elevation of a first distal end of the trough;

an angle actuator connected between the base and the trough and spaced apart from the trough's distal end for adjusting the elevation of a second proximal end of the trough; and

a first pivot between the trough and the distal end of the trough,

a second pivot between the trough and the proximal end of the trough,

wherein coordinated movement of the lift actuator and the angle control actuator permits elevation of the trough substantially parallel to the layers of tubulars,

inclination of the trough through pivoting about the first and second pivots, or both elevation and inclination of the trough.

3. The apparatus of claim 2 wherein the first pivot further comprises a rotationally actuable support arm connected between the lift actuator and the second actuator for a tipping rotation of the trough by the second actuator about the trough's longitudinal axis.

4. The apparatus of claim 3 wherein

the lift actuator further comprises

a lift arm which is vertically actuable relative to the base; and

a guide plate supported by the lift arm, the second actuator is supported by the lift arm and further comprises

a crank connected to the support arm and rotationally actuable relative to the lift arm.

5. The apparatus of claim 1 further comprising one or more spacers positioned between adjacent layers of tubulars for providing a rolling surface therebetween.

6. The apparatus of claim 5 wherein each of the one or more spacers further comprise a downwardly depending arm adjacent the trough to restrain tubulars from rolling toward the trough.

7. The apparatus of claim 1 wherein the base is a mobile trailer.

8. The apparatus of claim 1 wherein the trough is positioned along a midline of the base and the open top of the trough is capable of being tipped to both sides.

9. A method of stacking tubulars using the apparatus of claim 1 comprising:

orienting the trough to the supporting position with a tubular supported therein;

adjusting the elevation of the trough to the uppermost layer of the stack;

orienting the trough to the transfer position to unload the tubular from the trough; and

repeating the orienting, adjusting and orienting steps to transfer supported tubulars to the uppermost layer of the stack.

10. The method of claim 9 further comprising positioning two or more spacers spaced longitudinally between adjacent layers of tubulars to provide a rolling surface.

11. A method of unstacking tubulars using the apparatus of claim 1 comprising:

adjusting the elevation of the trough to the uppermost layer of tubulars in a stack of tubulars;

orienting the trough to receive a tubular;

rolling a tubular onto the trough from the plurality of tubulars in the uppermost layer;

unloading the tubular from the trough; and

repeating the adjusting, orienting, rolling and unloading steps to unstack the tubulars.

12. The apparatus of claim 1 further comprising:

a grabber spaced apart from the distal end of the trough, the grabber having a pivotal end connected to the base for pivotal movement of the grabber end towards and away from the distal end of the trough and having a grabber end for releasably engaging a tubular supported in the trough and extending beyond the proximal end of the trough, whereby coordinated movement of the proximal end of the trough and the grabber permits the grabber to move tubulars longitudinally towards and away from the trough respectively.

13. The apparatus of claim 2 further comprising:

a grabber spaced apart from the distal end of the trough, the grabber having a pivotal end connected to the base for pivotal movement of the grabber end and having a grabber end for releasably grabbing a tubular supported in the trough and extending beyond the proximal end of the trough; and

a third actuator for pivoting the grabber towards and away from the distal end of the trough,

whereby coordinated actuation of the first and third actuators permits the grabber to manipulate tubulars longitudinally towards and away from the trough respectively through grabbing and pivoting of the grabber.

14. The apparatus of claim 13 wherein the grabber end comprises a lower supporting jaw and an upper grabbing jaw for releasable engagement of a tubular positioned therebetween.

15. The apparatus of claim 14 wherein the grabber end is pivotally attached to the grabber for adjustment of the upper and lower jaws to conform substantially with the longitudinal axis of the tubular supported in the trough.

16. The apparatus of claim 15 further comprising a fourth actuator for extending the grabber end for adjusting the elevation the grabber head.

17. A method for moving a tubular longitudinally to an off-base location using the apparatus of claim 13 comprising:

positioning the base with the proximal end of the trough adjacent the off-base location;

elevating the proximal end of the trough with the tubular supported therein;

pivoting the grabber end toward the trough to position the grabber end below the proximal end of the supported tubular;

lowering the proximal end of the trough to engage the proximal end of the tubular with the grabber end;

grabbing the tubular with the grabber end; and

pivoting the grabber end away from the trough to manipulate the tubular longitudinally towards the adjacent off-base location.

18. The method of claim 17 further comprising:

engaging the proximal end of the tubular to an elevator at the off-base location;

releasing the proximal end of the tubular from the grabber end;

raising the tubular with the elevator for lifting the proximal end of the tubular from the grabber end, with the distal end of the tubular being slidably supported by the trough; and

lifting the distal end of the tubular out of the trough.

19. The method of claim 17 wherein prior to lifting the distal end of the tubular out of the trough, the method further comprising:

pivoting the grabber end toward the distal end of the tubular grabbing the distal end of the tubular with the grabber end;

pivoting the grabber end away from the trough to guide the distal end of the tubular as it moves away from the trough; and

guiding the tubular through the grabber end while lifting the distal end of the tubular out of the trough.

20. A method for moving a tubular longitudinally to the trough from an off-base location using the apparatus of claim 13 comprising the steps of:

positioning the proximal end of the trough adjacent the off-base location;

lowering the distal end of the tubular from the off-base location to towards the base;

grabbing a distal end of the tubular with the grabber end pivoted toward the off-base location;

guiding the distal end of the tubular with the grabber end to the trough;

pivoting the grabber end toward the trough to further manipulate the distal end of the tubular slidably and supportably into the trough;

releasing the grabber end from the tubular and lowering the proximal end of the tubular from the off-base location;

pivoting the grabber end away from the trough to position the grabber end below the proximal end of the tubular;

lowering the tubular from the off-base location and grabbing the proximal end of the tubular with the grabber end;

releasing the proximal end of the tubular from the off-base location; and

pivoting the grabber end towards the trough to move the tubular onto the trough until the tubular is supported therein.

21. The method of claim 20 wherein the off-base location further comprises an elevator for releasably engaging a proximal end of the tubular and wherein the lowering of the tubular from the off-base location further comprises:

engaging the proximal end of the tubular with the elevator at the off-base location;

lowering the elevator for

lowering the distal end of the tubular to the grabber end, and after guiding the distal end of the tubular to the trough, then

lowering the proximal end of the tubular to the grabber end as the distal end slides in the trough.

22. A method for moving tubulars longitudinally to and from an off-base location using the apparatus of claim 13 comprising:

positioning the base with the proximal end of the trough adjacent the off-base location;

unloading tubulars from the base comprising manipulating a tubular supported in the trough to the off-base location by elevating the proximal end of the trough with the tubular supported therein, pivoting the grabber end toward the trough to position the grabber end below the proximal end of the supported tubular, lowering the proximal end of the trough to engage the proximal end of the tubular with the grabber end, grabbing the tubular with the grabber end, and pivoting the grabber end away from the trough to manipulate the tubular longitudinally towards the adjacent off-base location, and releasing the tubular from the grabber end; and

loading tubulars to the base comprising manipulating the tubular suspended at the off-base location to the trough by lowering the distal end of the tubular from the off-base location towards the base, grabbing the distal end of the tubular with the grabber end, guiding the distal end of the tubular with the grabber end to the trough, and pivoting the grabber end toward the trough to further guide the distal end of the tubular slidably and supportably into the trough.

23. The method of claim 22 wherein:

prior to manipulating the tubular from the base to the off-base location, unloading the base further comprising adjusting the elevation of the trough to the uppermost layer of tubulars in a stack of tubulars; orienting the trough to receive a tubular;

rolling the tubular from the uppermost layer onto the trough and repeating the adjusting, orienting, rolling and manipulating steps to unload tubulars one-by-one to the off-base location; and

after manipulating the tubular from the off-base location to the trough,

unloading the trough comprising adjusting the elevation the trough to the uppermost layer of the stack, orienting the trough to the transfer position to unload the tubular from the trough to the uppermost layer, re-orienting the trough to the supporting position to receive another tubular, and repeating the elevation adjusting, orienting and re-orienting steps to transfer each manipulated tubular from the off-base location uppermost layer of the stack.