Spinning wrench systems

Abstract

An apparatus for rotating a tubular, the apparatus, in at least certain aspects including having a plurality of tubular-contacting rollers with one or more pairs of interlaced rollers. This Abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to apparatuses for connecting and disconnecting tubular members (e.g. casing, tubing, pipe, or drill pipe) and, in certain particular aspects to spinners, spinning wrenches, spinning tongs, iron roughnecks and methods of their use.

2. Description of Related Art

Drill pipe introduced into a well during oil and gas wellbore drilling is assembled in lengths joined with threaded joints. As the pipe is fed into a well, the sections of pipe are threaded together. When removing pipe, the threaded sections are disconnected and the sections of pipe stored. Inserting and removing the sections of drill pipe is called “tripping.” Threading and unthreading sections of pipe on tripping in and out of the well can be a difficult and cumbersome job. To make up the threads (or unscrew or break the threads) requires relatively high torque (rotational force). “Spinning” the pipe section after breaking (or before making up) the joints requires much less torque and is accomplished at much higher speed. Tightening and breaking joints requires a wrench to be tightly clamped on the pipe. In the early days, tightening and breaking was done manually with hand wrenches (more recently with power assisted wrenches). Spinning is a separate operation, long ago and in some places today done by wrapping a chain around a pipe and pulling the chain with a winch. Today power tong wrenches are used. Certain of these tongs have an open slot for pipe insertion and hydraulically powered clamps to grip the pipe. The pipe is rotated by a motor mechanically attached to the wrench. Such wrenches can develop high torque and work very well for making and breaking thread joints. Usually these wrenches work in combination with a backup wrench that holds the other section of threaded joint. The wrench is removed after making or breaking the threads, and a spinner (or top drive unit) spins out the threaded joint. Such wrenches are exemplified by the description in U.S. Pat. No. 4,348,920. Some types of these wrenches lack the capacity of handling different diameter pipe without changing pipe clamps. Since drill pipe, couplings, tapered pipe and joints are of different diameters, some wrenches handle widely varying diameters—from about 3.5 to about 9.5 inches in diameter. It is a great advantage for a wrench to be able to accommodate a range of diameters without having to change the clamps. U.S. Pat. No. 4,979,356 is an example of a power tong wrench which can not only accommodate the desired range of pipe diameters, but is also capable of making and breaking pipe sections and spinning the pipe. The ability to do both with the same wrench is highly desirable since it accomplishes with one connection step what previously required two or more connections with a wrench and spinner.

“Iron roughnecks,” which combine a torque wrench and a spinning wrench, have been used for connecting and disconnecting various tubulars, e.g. drilling components, such as drill pipe, in running a string of drill pipe or other pipe into or out of a well. The prior art includes a variety of iron roughnecks; see e.g. U.S. Pat. Nos. 4,023,449; 4,348,920; 4,765,401; 6,776,070, all of which are incorporated herein by reference in their entirety.

Various prior art iron roughnecks have a spinning wrench and a torque wrench mounted together on a carriage. For making or breaking threaded connections between two tubulars, e.g. joints of drill pipe, certain iron roughnecks have a torque wrench with two jaw levels. An upper jaw of the torque wrench is used to clamp onto a portion of an upper tubular, and a lower jaw clamps onto a portion of a lower tubular, e.g. upper and lower threadedly connected pieces of drill pipe. After clamping onto a tubular, the upper and lower jaws are turned relative to each other to break or make a connection between the upper and lower tubulars. A spinning wrench, mounted on the carriage above the torque wrench, engages the upper tubular and spins it until it is disconnected from the lower tubular (or in a connection operation, spins two tubulars together prior to final make-up by the torque wrench).

Certain iron roughnecks are mounted for movement from a wellbore center to a retracted position which does not interfere with or block performance of other operations relative to the well and rotating or driving apparatuses. Such a prior art system can be used for making and breaking joints in a main string or for connecting to or disconnecting from a tubular section located apart from a wellbore center, e.g. in a mousehole (or rathole) at a side of a well.

Certain prior art iron roughneck systems include a carriage for rolling on the surface of the rig floor along a predetermined path. In certain prior art systems a spinner and torque wrench are mounted for upward and downward movement relative to a carriage, for proper engagement with tubulars, and for tilting movement between a position in which their axis extends directly vertically for engagement with a vertical well pipe and a position in which the axis of the spinner and torque wrench is disposed at a slight angle to true vertical to engage and act against a pipe in an inclined mousehole. In certain prior art systems, a spinner is movable vertically with respect to a torque wrench.

The prior art discloses a variety of tongs and spinners for use in wellbore operations, e.g., but not limited to, as disclosed in and referred to in U.S. Pat. Nos. 6,684,737; 6,971,283; 5,660,087; 5,161,438; 5,159,860; 5,842,390; 5,245,877; 5,259,275; 5,390,568; 4,446,761; 4,346,629; 4,221,269; 3,892,148; 4,023,449; 5,044,232; 5,081,888; 5,167,173; 5,207,128; 5,409,280; 5,868,045; 6,966,385; 6,138,529; 4,082,017; 6,082,224; 6,213,216; 6,330,911; 6,668,684; 6,752,044; 6,318,214; and 6,142,041 (all said patents incorporated fully herein for all purposes).

There is a need, recognized by the present inventors, for an efficient tubular spinning system which can effectively handle a range of tubulars with varying diameters.

BRIEF SUMMARY OF THE INVENTION

The present invention, in certain embodiments, provides an apparatus for rotating a tubular, the apparatus including a plurality of adjacent driven rollers which can be interlaced to accommodate tubulars with a range of diameters. Such an apparatus may have a motor for each set of rollers. In certain aspects, this configuration of motors with interlacing rollers permits axes of adjacent motors to be relatively closer resulting in a more compact tool.

Accordingly, the present invention includes features and advantages which are believed to enable it to advance spinning system technology. Characteristics and advantages of the present invention described above and additional features and benefits will be readily apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments and referring to the accompanying drawings.

Certain embodiments of this invention are not limited to any particular individual feature disclosed here, but include combinations of them distinguished from the prior art in their structures, functions, and/or results achieved. Features of the invention have been broadly described so that the detailed descriptions that follow may be better understood, and in order that the contributions of this invention to the arts may be better appreciated. There are, of course, additional aspects of the invention described below and which may be included in the subject matter of the claims to this invention. Those skilled in the art who have the benefit of this invention, its teachings, and suggestions will appreciate that the conceptions of this disclosure may be used as a creative basis for designing other structures, methods and systems for carrying out and practicing the present invention. The claims of this invention are to be read to include any legally equivalent devices or methods which do not depart from the spirit and scope of the present invention.

What follows are some of, but not all, the objects of this invention. In addition to the specific objects stated below for at least certain preferred embodiments of the invention, there are other objects and purposes which will be readily apparent to one of skill in this art who has the benefit of this invention's teachings and disclosures. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide the embodiments and aspects listed above and: new, useful, unique, efficient, nonobvious spinners and systems and methods for making and breaking threaded connections between tubular members; and rollers for such spinners and systems with spaced-apart grooves and a projections permitting interlacing of the rollers.

The present invention recognizes and addresses the problems and needs in this area and provides a solution to those problems and a satisfactory meeting of those needs in its various possible embodiments and equivalents thereof. To one of skill in this art who has the benefits of this invention's realizations, teachings, disclosures, and suggestions, various purposes and advantages will be appreciated from the following description of preferred embodiments, given for the purpose of disclosure, when taken in conjunction with the accompanying drawings. The detail in these descriptions is not intended to thwart this patent's object to claim this invention no matter how others may later attempt to disguise it by variations in form or additions of further improvements.

The Abstract that is part hereof is to enable the U.S. Patent and Trademark Office and the public generally, and scientists, engineers, researchers, and practitioners in the art who are not familiar with patent terms or legal terms of phraseology to determine quickly from a cursory inspection or review the nature and general area of the disclosure of this invention. The Abstract is neither intended to define the invention, which is done by the claims, nor is it intended to be limiting of the scope of the invention or of the claims in any way.

It will be understood that the various embodiments of the present invention may include one, some, or all of the disclosed, described, and/or enumerated improvements and/or technical advantages and/or elements in claims to this invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A more particular description of embodiments of the invention briefly summarized above may be had by references to the embodiments which are shown in the drawings which form a part of this specification. These drawings illustrate certain preferred embodiments and are not to be used to improperly limit the scope of the invention which may have other equally effective or equivalent embodiments.

FIG. 1A is a front perspective view of a system according to the present invention.

FIG. 1B is a rear perspective view of the system of FIG. 1A.

FIG. 1C is a perspective view of a roller of the system of FIG. 1A.

FIG. 1D is a front view of the system of FIG. 1A.

FIG. 1E is a side view of the system of FIG. 1A.

FIG. 1F is a cross-section view along line 1E-1E of FIG. 1C.

FIG. 1G is a top view, partially cutaway, of part of the system of FIG. 1A.

FIG. 1H is a top view, partially cutaway, of part of the system of FIG. 1A.

FIG. 2A is a perspective view of part of the system of FIG. 1A.

FIG. 2B is a perspective view of part of the system of FIG. 1A.

FIG. 2C is a perspective view of part of the system of FIG. 1A.

FIG. 2D is a perspective view of part of the system of FIG. 1A.

FIG. 2E is a perspective view of part of the system of FIG. 1A.

FIG. 2F is a perspective view of a bogey limiter for use in the system of FIG. 1A.

FIG. 3A is a perspective view of part of the system of FIG. 2A.

FIG. 3B is a perspective view of part of the system of FIG. 2A.

FIG. 3C is a perspective view of part of the system of FIG. 2A.

FIG. 3D is a perspective view of part of the system of FIG. 2A.

FIG. 3E is a perspective view of part of the system of FIG. 2A.

FIG. 3F is a perspective view of part of the system of FIG. 2A.

FIG. 4A is a perspective view of part of the system of FIG. 1A.

FIG. 4B is a perspective view of part of the system of FIG. 1A.

FIG. 5 is a side schematic view of a system according to the present invention.

FIG. 6 is a side schematic view of a system according to the present invention.

FIG. 7A is a front perspective view of a spinner system according to the present invention.

FIG. 7B is a top view of the system of FIG. 7A.

FIG. 7C is a rear view of the system of FIG. 7A.

FIG. 7D is a rear view of the system of FIG. 7A.

FIG. 7E is a front view of the system of FIG. 7A.

FIG. 7F is a bottom view of the system of FIG. 7A.

FIG. 7G is a top partially cutaway view of the system of FIG. 7A.

FIG. 7H is a top cross-section view of the system of FIG. 7A.

FIG. 8A is a perspective view of part of a clamp apparatus of the system of FIG. 7A.

FIG. 8B is a top view of the part of FIG. 8A.

FIG. 8C is a top view of part of the clamp apparatus of FIG. 8A.

FIG. 8D is a cross-section view along line 8D-8D of FIG. 8B.

FIG. 8E is a perspective view of part of the clamp apparatus of the system of FIG. 8A.

FIG. 8F is a side view of the clamp apparatus of FIG. 8A.

FIG. 8G is a cross-section view of the clamp apparatus as shown in FIG. 8F.

FIG. 8H is a top view of the clamp apparatus of FIG. 8A.

FIG. 8I is a cross-section view of the clamp apparatus as shown in FIG. 8H.

FIG. 8J is a cross-section view of the clamp apparatus as shown in FIG. 8I.

Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. Various aspects and features of embodiments of the invention are described below and some are set out in the dependent claims. Any combination of aspects and/or features described below or shown in the dependent claims can be used except where such aspects and/or features are mutually exclusive. It should be understood that the appended drawings and description herein are of preferred embodiments and are not intended to limit the invention or the appended claims. On the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims. In showing and describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.

As used herein and throughout all the various portions (and headings) of this patent, the terms “invention”, “present invention” and variations thereof mean one or more embodiment, and are not intended to mean the claimed invention of any particular appended claim(s) or all of the appended claims. Accordingly, the subject or topic of each such reference is not automatically or necessarily part of, or required by, any particular claim(s) merely because of such reference. So long as they are not mutually exclusive or contradictory any aspect or feature or combination of aspects or features of any embodiment disclosed herein may be used in any other embodiment disclosed herein.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1A-1H illustrate a spinner system 10 according to the present invention which has a main frame 12 with a crossmember 13 connecting two spaced-apart upright beams 14 releasably connected by chains 16 to a hanging bracket 18. Clamping cylinder assemblies 20 disposed between frame members or plates 22, 24 move arms 26, 28 which, in turn, move bogeys 30, 32 to move rollers mounted thereon (described below) into contact with a tubular to be rotated. Tubulars can include pipe, drill pipe, tubing, and casing. Each arm 26, 28 includes a top plate (26a, 28a) and a bottom plate (26b, 28b). It is within the scope of the present invention for any part or piece or component that includes multiple items, e.g. (but not limited to) a component with multiple plates, to instead be made as a single integral component, e.g. a casting. Thus, e.g., a part with multiple plates connected together, e.g. welded together, may e a single manufactured casting.

Chains or cables connected to torque reaction links 34, 36 releasably connect the system to a support column or other structure (see also link 34, FIG. 2D). Optional covers 41-44 shield motors 51-54 which rotate rollers 61-64. The arms 26, 28 are pivotably secured to trunnions 23, 25 of trunnion blocks 27, 29. An end 31, 33 of each cylinder assembly 20 is rotatably secured by a pin 35 to a cylinder mount 37.

The plates 22, 24 have slots 21a, 21b (respectively—see FIGS. 1A, 2A) in which a pin 39 moves. The pin 39 extends through a hole 73 in an upper plate 30a and a hole 74 in a lower plate 30b of the left hand bogey 30 to secure the left hand bogey 30 to the plates 22, 24. The slots 21a, 21b limit movement of the pin 39 thereby limiting movement of the left hand bogey 30. This also limits the movement of the rollers 63, 64 rotatably connected to the left hand bogey 30 (as described in detail below). Cover mount blocks 49 on the plate 30a provide structure to which the cover 43 is secured. The cover 44 is secured to the plates 26a, 26b. The left hand bogey 32 pivots about a pin 48. The pin 48 extends through holes 88 in the plates 26a, 26b.

The right hand bogey 32 is “free floating”” in the sense that it is not slaved to anything and can pivot, e.g. up to 10 degrees with respect to the center line of the system. The right hand bogey 32 freely about a pin 45. The right hand bogey 32 has a top plate 32a and a bottom plate 32b. The pin 45 passes through holes 71, 72 (see FIG. 2C) to secure the right hand bogey 32 to the plates 22, 24. The cover 42 is secured to mount blocks 75. The cover 42 is secured to the arms 26, 28.

The motors 53, 54 are on top of the left hand bogey 32 and the motors 51, 52 are on top of the right hand bogey 30. As shown in dotted line in FIG. 1D a flow divider 170 receives power fluid (e.g. hydraulic fluid under pressure from a rig source). Power fluid from the flow divider 170 is provided via connections 172 to the motors 51-54 and to the clamping cylinders 20. As shown the motors 51-54 are located above corresponding rollers; but it is within the scope of the present invention to locate the motors at any convenient location whether above the rollers or not.

The roller 62 is mounted with portions in the holes 76a, 76b (see FIG. 2C); the roller 61 is mounted with portions in the holes 77a, 77b; the roller 64 is mounted with portions in the holes 78a, 78b (see FIG. 2B); and the roller 63 is mounted with portions in the holes 79a, 79b.

The pin 47 extends through a hole 94 in the plate 26a, through a hole (not shown) in the plate 26b and through a hole 87 in the plate 22 and a hole 88 in the plate 24 to pivotably connect the arm 26 to the plates 22, 24. The pin 46 extends through a hole 89 in the arm 28, through holes 85, 86 in the plates 22, 24 and through a lower hole 101 in the plate 28b to pivotably pin the arm 28 to the plates 22, 24.

FIG. 2E shows the arm 28 (the arm 26 is a mirror image of the arm 28).

FIG. 2F shows a bogey limiter 110 (see also in FIG. 1A) which prevents the bogey 32 from rotating more than a certain amount, e.g. within a 10 degree range of motion. In certain aspects, the bogey limiter is deleted.

FIGS. 3A-3F show a roller 120 and associated parts. The roller 120 may be any of the rollers 61, 62, 63, 64 (or any roller herein). The roller 120 has a body 122 with a plurality of spaced-apart projections 124-127. Optionally, the projections have a series of spaced-apart grooves 128 or 129. It is believed that the projections with these grooves will function similarly to the treads of a tire on a wet surface and a surface film on the projections will be forced into the grooves thereby increasing friction between the rollers and a tubular to be rotated.

The roller body 122 has a recess 139 and a slot 131 which receives a corresponding member 132 (into slot 131) and a corresponding end (into recess 139) of a drive spindle 133. The drive spindle 133 passes through an upper bearing housing 134. The drive spindle 133 is connected to a drive shaft of a motor (e.g. a motor 51-54). The motor rotates the drive spindle 133 which in turn rotates the roller 120. The motor can be bolted to the upper bearing housing 134.

The roller 120 rotates on a lower spindle 135 which rotates in a lower bearing housing 136 whose bottom is covered with a cover 137. The upper bearing housing 134 and the lower bearing housing 136 are connected to a corresponding bogey (see any bogey in the system of FIG. 1A).

Between the projections 124-127 are a series of spaced-apart areas 141, 142, and 143 and an area 144 beneath the lowermost projection 127. Projections on an adjacent roller like the projections 124-127 can be received in and fit within the areas 141-144 as two rollers are moved toward each other. The areas 141-144 are recessed with respect to the outer surfaces of the projections 124-127. It is within the scope of the present invention for a first roller to have one projection (or at least one projection) and an adjacent roller to have one groove (or at least one groove), with the one projection projecting into and received within the one groove so that the two rollers are interlaced (or for the at least one projection to project into the at least one groove or for each of a series of spaced-apart projections on a first roller to project into and be received within a corresponding groove of a series of spaced apart grooves on a second adjacent roller. Also, a spinning wrench system according to the present invention can have two pairs of such rollers, the two pairs movable to contact each other so that a first roller of each pair interlaces with each other and a second roller of each pair interlaces with each other.

FIGS. 1F-1H illustrate movement of the arms 26, 28; the bogeys 30, 32; and the rollers 61-64 with respect to the frame 12 and with respect to a tubular T (see FIG. 1H).

In FIGS. 1F and 1G the pin 39 is at one end 21c of the slots 21a, 21b (end 21c of the slot 21a) which positions the rollers 63, 64 at an angle to a central axis A of the system 10 (e.g. in one particular aspect four degrees). The clamping cylinders 20 have not been actuated to move the arms 26, 28, the bogeys 30, 32 and the rollers 61-64 inwardly toward the tubular T.

As shown in FIG. 1H, the clamping cylinders 20 have been actuated, pivoting the arms 26, 28 to move the bogeys 30, 32 and the rollers 61-64 moving the rollers 61, 62 toward the rollers 63, 64. The rollers 61, 63 are interlaced with each other with the projections on one roller received in the valleys of the other roller. The rollers 62, 64 are interlaced with each other with the projections on one roller received in the valleys of the other roller. As shown in FIG. 1F, the rollers 61, 62 are mounted so that they are interlaced with each other with the projections of one roller received in the valleys of the other roller; as are the rollers 63, 64. All of the rollers contact the tubular T and, when rotated, the rollers rotate the tubular T. The interlacing facilitates maintenance of spacing apart of the rollers around a tubular and helps prevent the rollers from slipping on a tubular or from spitting a tubular out the front of the system.

As shown in FIG. 1H, the pin 39 has moved to an opposite end 21d of the slots 21a, 21b guiding the orientation of the bogey 30 and rollers 63, 64 at a desired location. The available stroke of the cylinders stops movement of the bogey 30 at a “clamp off” position or “clamp on without pipe” position. An axis B of the rollers 63, 64 is parallel to the axis A insuring the rollers are maintained horizontal to the central axis of the system at all times. In one aspect, the bogey pivot pins 345, 348 each will move through an arc while a theoretical pipe center remains in position relative to the system. This results in a small variable forward/rearward offset between the bogey pivot pins 345, 348 and the theoretical pipe center. This offset can be reduced or eliminated by allowing the bogies to angle slightly either side of perpendicular to centreline. This angle is governed by the shape of the guide slot (slots 332a, 332b) acting with the pin 339 of the bogey 332. The slots 332a, 332b are shaped to “open up” the angle of the bogey 332 in a “clamp off” position (when the bogies are moved away from the theoretical pipe center).

As shown in FIG. 1H, each roller 61-64 has an equal amount of contact with the tubular T so that static clamp forces are applied equally by all four rollers, including those on the right hand bogey (since the right hand bogey floats free, the left hand bogey allows all rollers to contact a tubular with equal force). During spinning, rollers diagonal to each other have equal clamp force, but the leading and trailing rollers on each bogey have different contact force onto a pipe.

FIGS. 4A and 4B are perspective views of the cover 41.

FIG. 5 shows a system 200 according to the present invention for connecting and disconnecting tubulars TB and TL While a spinning system 210 (shown schematically) according to the present invention spins the tubular TB a wrench 202 (e.g. any suitable wrench or tong) holds the tubular TL. A hanger 204 permits connection of the system 210 to another member or structure. The wrench 202 is connected to the spinning system 210 with a connection 206 and a spring 208. The spinning system 210 may include any spinner according to the present invention, including but not limited to, that of FIG. 1A or of FIG. 7A.

FIG. 6 show a system 10 according to the present invention (like systems disclosed in co-owned U.S. Pat. Nos. 7,185,547 and 7,062,991 incorporated fully herein for all purposes) which has a carriage 20 which is movably connected for up/down vertical movement to a column 14 and which can also translate horizontally on a rig floor RF for movement toward and away from a drill pipe D of a drill string DS in a well W. Support arms 22, 24 (two each) are pivotably connected at one end to a base 23 of the carriage 20 and at their other ends to a support 25. Optionally, only one support arm is used or two arms in parallel are used. A connector 21 is removably emplaceable in a socket 29 to mount the system on the rig.

A torque wrench 11 (e.g. as disclosed in co-owned U.S. Pat. Nos. 7,185,547 and 7,062,991, or in any prior art cited therein) and a spinner 12 (any according to the present invention) are connected to the carriage 20 and are movable by a power mechanism PM toward and away from the column 14 by moving the support arms 22, 24. Optionally, a known torque wrench may be used, e.g. instead of the torque wrench 100. The spinner is movable up and down on the spin wrench carriage 25 toward and away from the torque wrench. A control console CS for the system 10 is shown schematically in FIG. 1B. Optionally, the console CS communicates by wire or wirelessly with the torque wrench 100 and/or the spinner 12 and/or the control console CS is located remotely from it.

FIGS. 7A-7H illustrate a spinner system 300 according to the present invention which has a frame 312 with a crossmember 313 connecting two spaced-apart beams 314 releasably connected by connectors 316 to a hanging bracket 318. Clamping cylinder assemblies 320 disposed between frame members 322, 324 are connected to and selectively move arms 326, 328 which, in turn, move bogeys 330, 332 to move rollers mounted thereon (described below) into contact with a tubular to be rotated. Cylinder yoke bushings 334 of the clamping cylinder assemblies 320 received and held in corresponding holes 326h, 328h in plates 326a, 326b, 328a, 328b of the arms 32b, 328, respectively, to pivotably connect the arms 326, 328 to the clamping cylinder assemblies 320. A center member 321 connected to both clamping cylinder assemblies 320 is secured to a frame center mount 335. It is within the scope of the present invention to use a single cylinder assembly instead of the two cylinder assemblies 320.

Each arm 326, 328 includes a top plate (326a, 328a) and a bottom plate 326b, 328b). These plates 326a, 326b, 328a, 328b are pivotably mounted to and between the frame members 322, 324 with pins 325.

Covers 341-344 shield motors 351-354 and rollers 361-364 which are rotated by the motors 351-354. The bogeys 330, 332 are pivotably connected to the arms.

The plates 322, 324 have slots 322a, 324a respectively in which a pin 339 moves. The pin 339 extends through a hole 373 in an upper plate 332a and a hole 374 in a lower plate 332b of the bogey 332. The slots 332a, 332b guide movement of the pin 339 thereby guiding movement of the bogey 332. This also guides the movement of the rollers 363, 364 rotatably connected to the bogey 332 (as described in detail below). Cover mount blocks 349 on the plate 332a provide structure to which the cover 343 is secured. The cover 344 is secured to the arm 328. The bogey 332 pivots about a pin 348. The pin 348 extends through holes 388 in the plates 328a, 328b.

The bogey 330 is “free floating”” in the sense that it is not slaved to anything and can pivot with respect to the arm 326 and can pivot, e.g. up to 10 degrees, with respect to the center line of the system. The bogey 330 freely pivots about a pin 345. The bogey 330 has a top plate 330a and a bottom plate 330b. The pin 345 passes through holes 371, 372 to secure the bogey 330 to the arm 326. The cover 341 is secured to mount blocks 375. The cover 342 is secured to the arm 326.

The motors 353, 354 are on top of the bogey 332; and the motors 351, 352 are mounted on top of the bogey 330. A flow divider 370 receives power fluid (e.g. hydraulic fluid under pressure from a rig source). Power fluid from the flow divider 370 is provided via connections 372 to the motors 351-354. Power fluid from the flow divider 370 is provided to the clamping cylinder assemblies 320 via connections 374. As shown the motors 351-354 are located above corresponding rollers; but it is within the scope of the present invention to locate the motors (or a single motor or two motors) at any convenient location whether above the rollers or not, below the rollers, or adjacent the rollers; or to use a single motor for driving multiple rollers, e.g., but not limited to, a first motor for driving the rollers on one side, e.g. via appropriate gearing, and a second motor for driving the rollers on the other side. One motor can drive multiple rollers, e.g. via gearing, in synchronization.

The roller 62 is mounted with portions in the holes 76a, 76b (see FIG. 2C); the roller 61 is mounted with portions in the holes 77a, 77b; the roller 64 is mounted with portions in the holes 78a, 78b (see FIG. 2B); and the roller 63 is mounted with portions in the holes 79a, 79b.

A pin 347 extends through holes in the plates 322, 324 and through holes in the plates 326a, 326b to pivotably connect the arm 326 to the plates 322, 324. A pin 346 extends through holes in the plates 328a, 328b and through holes in the plates 322, 324 to pivotably connect the arm 328 to the plates 322, 324.

The rollers 361-364 may be like any roller disclosed herein according to the present invention (e.g., but not limited to, the rollers shown in FIGS. 1A and 3C). For example, the roller 363 has a plurality of spaced-apart projections 377 and a plurality of spaced-apart recesses 379. Any of the rollers 361-364 may have grooves like the grooves 128 or 129 described above. The rollers 361-364 may have the associated parts as shown in FIGS. 3A-3F.

As shown in FIGS. 7E-7H, the clamping cylinder apparatuses have been activated to move the arms 326, 328, bogeys 330, 332, and rollers 361-364 inwardly to clamp a tubular T for spinning. The pin 339 has guided the rotation of the bogey 332 about the pivot pin 348. The pin 337 prevents the bogey from trying to rotate in the opposite direction to the rollers 363 and 364. The pin 339 slides along the slots 332a, 324a as the clamp cylinders are operated, but it is the end stroke of the clamp cylinders and not the slots that limit the extremes of clamping movement. The bogey 332 can be considered as the “master” while the bogey 330 is the “slave”. The bogey 332 aligns the spinner unit precisely with the tubular centerline irrespective of the tubular diameter. The bogey 330 then passively self aligns as clamp force is applied.

The rollers 361-364 are interlaced as shown in FIGS. 7E-7H. The roller 361 interlaces with the roller 362 and with the roller 363. The roller 362 also interlaces with the roller 364. The roller 364 interlaces with the rollers 362 and 363.

In certain aspects, interlacing of rollers works like treads on a tire; i.e. contact area is reduced and local contact pressure is increased, while surface contamination tends to be pressed into the grooves.

Any suitable powered cylinder assemblies may be used for the clamping cylinder assemblies 320. In one particular aspect, as shown in FIGS. 7H and 8A-8D, each clamping cylinder assembly 320 has a housing 320a within which a piston 320p is movably mounted. To accommodate the pivoting of an arm 326 or arm 328 to which the housing 320a is connected, a pivotable connector 320c connects the piston 320p to the center member 321.

The connector 320c has a first member 320d with a ball end 320e and a second member 320f with a ball end 320g. A pin 320h pins an end 320i of the second member 320f to the first member 320d. The ball end 320e of the first member is movable in a first spherical bearing 320j connected to the piston 320p. The ball end 320g is movable in a second spherical bearing 320k connected to the center member 321. The members 320d, 320f act like a rod connected to the piston 320p. Thus the housing 320a is pivotable with respect to the housing center member 321, allowing the cylinder to accommodate a certain amount of both angular and parallel misalignment without transferring significant loads to the cylinder slides and seals. Thus the fixed cylinders using the hemispherical bearings 320e, 320g are substantially or almost totally isolated from side loads (e.g. loads perpendicular to a longitudinal axis of the members 320d, 320f which could create a moment which would be resisted by sliding surfaces of the piston). In certain aspects such side or lateral loads can be the result of wear of moving parts; production or installation tolerances; mechanical deflection under loading; or incorrect operation.

A seal 320m (e.g., but not limited to, a rubber bellows apparatus) seals the housing-320a-center-mount-321 interface and prevents moisture and contamination from reaching the connector system and ball joints. A retaining ring 321a screwed onto the center member 321 locks the ball end of the connector to the center member 321 to retain the spherical bearing 320k and resists cylinder retract loads when pressure is applied to the return side of the piston (pressure in the volume space 320x).

Pressurized oil from the flow divider 370 enters a cylinder retract port 320w to move the housing inwardly to unclamp the rollers from a tubular. The rollers are applied by supplying pressurized oil from the flow divider 370 to the rear of the piston via one of the two cylinder extend ports 320r. Channels 320s within the body of the cylinder lead this oil to the rear of the piston. Oil within the space 320x is pressed out of the cylinder retract port as the cylinder extends.

In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. §102 and satisfies the conditions for patentability in §102. The invention claimed herein is not obvious in accordance with 35 U.S.C. §103 and satisfies the conditions for patentability in §103. This specification and the claims that follow are in accordance with all of the requirements of 35 U.S.C. §112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes. What follows are some of the claims for some of the embodiments and aspects of the present invention, but these claims are not necessarily meant to be a complete listing of nor exhaustive of every possible aspect and embodiment of the invention. It is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. In this patent document, the word “comprising” is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one of the elements.

Claims

1. A spinning wrench system for connecting and disconnecting threaded tubulars, the spinning wrench system comprising

a first mount member,

a first roller rotatably mounted to the first mount member, the first roller comprising a body with at least one projection,

a second roller rotatably mounted to the first mount member, the second roller having at least one groove sized and located for receipt therein of the at least one projection of the first roller,

a portion of the at least one projection of the first roller projecting into and received in the at least one groove of the second roller, and

the first roller and the second roller movable to contact a tubular and rotatable to rotate the tubular.

2. The spinning wrench system of claim 1 further comprising

a second mount member,

a third roller rotatably mounted to the second mount member, the third roller comprising a body with at least one projection,

a fourth roller rotatably mounted to the second mount member, the fourth roller having at least one groove sized and located for receipt therein of the at least one projection of the third roller,

a portion of the at least one projection of the third roller projecting into and received in the at least one groove of the fourth roller, and

the third roller and the fourth roller movable to contact the tubular and rotatable to rotate the tubular.

3. The spinning wrench system of claim 2 further comprising

a base,

a first arm, the first mount member connected to the first arm, the first arm movably connected to the base,

a second arm, the second mount member connected to the second arm, the second arm movably connected to the base, and

the first arm and the second arm movable to move the rollers into contact with the tubular to rotate the tubular.

4. The spinning wrench system of claim 3 wherein

the first arm and the second arm are movable to bring the first roller into contact with the fourth roller so that a portion of the at least one projection of the first roller projects into and is received within the at least one groove of the fourth roller, and

the third roller is movable to contact the second roller so that a portion of the at least one projection of the third roller projects into and is received within the at least one groove of the second roller.

5. The spinning wrench system of claim 1 wherein

the at least one projection of the first roller is a series of spaced-apart projections,

the at least one groove of the second roller is a series of spaced-apart grooves, and

each groove of the series of spaced-apart grooves corresponds to a corresponding projection of the series of spaced-apart projections.

6. The spinning wrench system of claim 3 further comprising

movement apparatus connected to the first arm and to the second arm for selectively moving the first arm and the second arm.

7. The spinning wrench system of claim 6 wherein the movement apparatus includes

a base,

a center member connected to the base,

a first powered cylinder apparatus connected to the center member and to the first arm for moving the first arm, and

a second powered cylinder apparatus connected to the center member and to the second arm for moving the second arm.

8. The spinning wrench system of claim 7 further comprising

a first connector pivotably connecting the first powered cylinder apparatus to the center member, and

a second connector pivotably connecting the second powered cylinder apparatus to the center member.

9. The spinning wrench system of claim 7 wherein

each powered cylinder apparatus includes a housing and a piston movably mounted in the housing,

each connector including a rod member within the housing and connected to the piston, each rod member having a first end and a second end,

each first end mounted on a first hemispherical bearing, and each second end mounted in a second hemispherical bearing so that each of the powered cylinder apparatuses is substantially isolated from lateral loading.

10. The spinning wrench system of claim 2 wherein each roller has a surface area and the rollers are movable to contact the tubular with each roller having a similar amount of surface area in contact with the tubular.

11. The spinning wrench system of claim 3 further comprising

guiding apparatus for guiding movement of the second mount member.

12. The spinning wrench system of claim 11 wherein the guiding apparatus includes

a slot in the base,

a pin on the second mount member,

the pin projecting into the slot and movable therein, and

the slot guiding movement of the pin to guide movement of the second mount member.

13. The spinning wrench system of claim 3 wherein the first mount member is pivotably connected to the first arm so that the first mount member is free floating with respect to the first arm.

14. The spinning wrench system of claim 12 wherein the first mount member is movable to align the spinning wrench system with respect to centerline of a tubular to be rotated by the spinning wrench system.

15. The spinning wrench system of claim 3 wherein the spinning wrench system has a central axis and the rollers are positioned parallel to the central axis and are movable at a right angle to the central axis.

16. The spinning wrench system of claim 1 further comprising

drive apparatus for rotating the rollers.

17. The spinning wrench system of claim 1 further comprising

the drive apparatus including a separate motor for driving each roller.

18. A spinning wrench system for connecting and disconnecting threaded tubulars

a first mount member,

a first roller rotatably mounted to the first mount member, the first roller comprising a body with at least one projection,

a second roller rotatably mounted to the first mount member, the second roller having at least one groove sized and located for receipt therein of the at least one projection of the first roller,

a portion of the at least one projection of the first roller projecting into and received in the at least one groove of the second roller,

the first roller and the second roller movable to contact a tubular and rotatable to rotate the tubular,

a second mount member,

a third roller rotatably mounted to the second mount member, the third roller comprising a body with at least one projection,

a fourth roller rotatably mounted to the second mount member, the fourth roller having at least one groove sized and located for receipt therein of the at least one projection of the third roller,

a portion of the at least one projection of the third roller projecting into and received in the at least one groove of the fourth roller,

the rollers movable to contact a tubular and rotatable to rotate the tubular,

a base,

a first arm, the first mount member connected to the first arm, the first arm movably connected to the base,

a second arm, the second mount member connected to the second arm, the second arm movably connected to the base,

the first arm and the second arm movable to move the rollers mounted thereon into contact with the tubular to rotate the tubular,

wherein the first arm and the second arm are movable to bring the first roller into interlacing contact with the fourth roller and the second roller into interlacing contact with the third roller,

the at least one projection of the first roller and of the third roller is a series of spaced-apart projections,

the at least one groove of the second roller and of the fourth roller is a series of spaced-apart grooves,

each groove of each series of spaced-apart grooves corresponds to a projection of each series of spaced-apart projections,

movement apparatus connected to the first arm and to the second arm for selectively moving the first arm and the second arm,

the movement apparatus including

a base,

a center member connected to the base,

a first powered cylinder apparatus connected to the center member and to the first arm for moving the first arm,

a second powered cylinder apparatus connected to the center member and to the second arm for moving the second arm, and

drive apparatus for rotating the rollers.

19. A method for rotating a tubular with a spinning wrench system, the method comprising

positioning a tubular with respect to rollers of a spinning wrench system so that the rollers are interlaced and drivingly contact the tubular, the spinning wrench system comprising a first mount member, a first roller rotatably mounted to the first mount member, the first roller comprising a body with at least one projection, a second roller rotatably mounted to the first mount member, the second roller having at least one groove sized and located for receipt therein of the at least one projection of the first roller, a portion of the at least one projection of the first roller projecting into and received in the at least one groove of the second roller, and the first roller and the second roller movable to contact a tubular and rotatable to rotate the tubular, the spinning wrench system including driving apparatus for rotating the rollers, and

rotating the rollers with the driving apparatus thereby rotating the tubular.

20. The method of claim 19 wherein the driving apparatus includes a separate drive motor for each roller and each roller is driven by a respective single motor.

21. A system for connecting and disconnecting threaded tubulars, the system comprising

a base,

a spinning wrench system connected to the base,

a torque wrench system connected to the base, the torque wrench system for holding a first tubular while the spinning wrench system spins a second tubular with respect to the first tubular,

the spinning wrench system comprising

a first mount member,

a first roller rotatably mounted to the first mount member, the first roller comprising a body with at least one projection,

a second roller rotatably mounted to the first mount member, the second roller having at least one groove sized and located for receipt therein of the at least one projection of the first roller,

a portion of the at least one projection of the first roller projecting into and received in the at least one groove of the second roller, and

the first roller and the second roller movable to contact a tubular and rotatable to rotate the tubular.

22. A spinning wrench system for connecting and disconnecting threaded tubulars, the spinning wrench system comprising

a first mount member,

a second mount member,

first roller apparatus rotatably mounted to the first mount member,

second roller apparatus rotatably mounted to the second mount member,

the first roller apparatus and the second roller apparatus movable to contact a tubular and rotatable to rotate the tubular,

a base,

a first arm, the first mount member connected to the first arm, the first arm movably connected to the base,

a second arm, the second mount member connected to the second arm, the second arm movably connected to the base,

the first arm and the second arm movable to move the respective roller apparatus into contact with the tubular to rotate the tubular,

movement apparatus connected to the first arm and to the second arm for selectively moving the first arm and the second arm,

a center member connected to the base,

a first powered cylinder apparatus connected to the center member and to the first arm for moving the first arm,

a second powered cylinder apparatus connected to the center member and to the second arm for moving the second arm,

a first connector connecting the first powered cylinder apparatus to the center member, and

a second connector connecting the second powered cylinder apparatus to the center member,

each powered cylinder apparatus including a housing and a piston movably mounted in the housing,

each connector including a rod member, each rod member having a first end and a second end, and

each first end mounted on a first hemispherical bearing, and each second end mounted in a second hemispherical bearing so that each of the powered cylinder apparatuses is substantially isolated from lateral loading.

23. A system for connecting and disconnecting threaded tubulars, the system comprising

a base,

a spinning wrench system connected to the base,

a torque wrench system connected to the base, the torque wrench system for holding a first tubular while the spinning wrench system spins a second tubular with respect to the first tubular,

the spinning wrench system comprising

a first mount member with a first roller apparatus rotatably mounted thereto,

a second mount member with a second roller apparatus rotatably mounted thereto,

the first mount member and the second mount member movable so that each roller apparatus contacts a tubular,

a base,

a first arm, the first mount member connected to the first arm, the first arm movably connected to the base,

a second arm, the second mount member connected to the second arm, the second arm movably connected to the base,

the first arm and the second arm movable to move their respective mount member and corresponding roller apparatus into contact with the tubular to rotate the tubular,

movement apparatus connected to the first arm and to the second arm for selectively moving the first arm and the second arm,

a first powered cylinder apparatus connected to the first arm for moving the first arm,

a second powered cylinder apparatus connected to the second arm for moving the second arm,

a first connector connecting the first powered cylinder apparatus to the base,

a second connector connecting the second powered cylinder apparatus to the base,

each powered cylinder apparatus including a housing and a piston movably mounted in the housing,

each connector including a rod member connected to a corresponding piston, each rod member having a first end and a second end, and

each first end mounted on a first hemispherical bearing and each second end mounted in a second hemispherical bearing so that each of the powered cylinder apparatuses is substantially isolated from lateral loading.