Coil Tube Injector System

Abstract

A coil tube injector head comprising at least two gearbox units, wherein each gearbox unit drives a gripper assembly comprising a plurality of gripper assembly links. The gripper assembly links comprise a gripper surface that engages a length of coil tubing and one or more roller bearings that engage a bearing plate. The coil tube injector head further comprises a skid plate that is coupled to the bearing plate and receives pressure from one or more traction cylinders. The assembly of the claimed embodiments further allows for ease of maintenance and service of the coil tube injector by operators in the field of oil and gas production.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/811,219, filed Apr. 12, 2013, which is incorporated herein by reference for all purposes.

BACKGROUND

Hydrocarbons are an important resource which are often retrieved from ground by performing various subterranean operations. When performing subterranean operations, coil tube injector heads may be used to direct coil tubing (e.g., tubing which may be in a range of from approximately 1″ to approximately 3½″) into and out of a wellbore. The injectors provide a means of gripping the tubing to perform a controlled feeding operation. Injector heads are rated against the pushing/pulling force they can generate and the feedrate at which the tubing can be passed.

A complete injector head may comprise several components. For instance, the injector head may include an injector head assembly; a crash frame (providing a degree of mechanical protection during service); a service platform (allowing the operators to manage the operation of coil tube injection during service); and a gooseneck (which controls the feed of the tubing into the injector from a separate coil tube spool).

The basic premise of a coil tube injector is to simply grip the tubing with sufficient traction so that it does not slip when performing the desired subterranean operations, and then either pushing the tubing into a well or extracting it out. To achieve this goal, generally there are two sets of grippers, attached to a chain drive mechanism. The drives are generally hydraulically powered and when combined with a reduction gearbox provide sufficient torque to adequately move the loads. It is desirable to have an injector head which can operate smoothly and which can be easily maintained and serviced without disrupting ongoing subterranean operations.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete and thorough understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings.

FIG. 1 is an illustration of a coil tube injector configuration in accordance with certain embodiments of the present disclosure.

FIG. 2A is a first perspective view of the injector head assembly of FIG. 1 in accordance with an illustrative embodiment of the present disclosure.

FIG. 2B is a second perspective view of the injector head assembly of FIG. 1 in accordance with an illustrative embodiment of the present disclosure.

FIG. 2C is a third perspective view of the injector head assembly of FIG. 1 in accordance with an illustrative embodiment of the present disclosure.

FIG. 3A is a side close up view of the injector head assembly of FIGS. 2A-C in accordance with certain embodiments of the present disclosure.

FIG. 3B is a cross-sectional view of the injector head assembly of FIG. 3A in accordance with certain embodiments of the present disclosure.

FIG. 3C is a cross-sectional view of the injector head assembly of FIG. 3A with one side of the crash frame removed, in accordance with certain embodiments of the present disclosure.

FIG. 4 is a close up view of one of the chain links of a gripper/chain assembly in accordance with certain embodiments of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present invention are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve the specific implementation goals, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

To facilitate a better understanding of the present invention, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the invention. Embodiments of the present disclosure may be used with any wellhead system. Embodiments of the present disclosure may be applicable to horizontal, vertical, deviated, or otherwise nonlinear wellbores in any type of subterranean formation. Embodiments may be applicable to injection wells as well as production wells, including hydrocarbon wells.

The terms “couple” or “couples” as used herein are intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect mechanical or electrical connection via other devices and connections.

The methods and systems disclosed herein are not limited to any particular unit size. For instance, in certain implementations, the injector head unit may be an ‘80 k’ (80,000 psi) unit. However, the design concept can easily be upscaled and downscaled to suit the actual requirements. The methods and systems disclosed herein are directed to an actual operation constraint with regard to ease of operation and maintenance, making a ‘simple’ unit which is easily maintained and therefore, can be kept in production.

A coil tube injector in accordance with an illustrative embodiment of the present disclosure is generally denoted with reference numeral 100 in FIG. 1. As shown in FIG. 1, a coil tube injector 100 is comprised of an injector head assembly 102, a crash frame 104 that provides mechanical protection to the injector head assembly 102, a service platform 106 that allows the operators to perform service on the coil tube injector 100 and manage the operation of the coil tube injector 100 during service, and a gooseneck 108 that controls the feed of the coil tubing 110 into the injector head assembly 102 from an external coil tube spool (not shown). Specifically, a spool (not shown) may be disposed near the coil tube injector 100 and a coil tubing 110 may be drawn from the spool and directed over the gooseneck 108, and through the injector head assembly 102, into the wellbore.

FIGS. 2A-C depict different perspectives of a close up view of the injector head assembly 102 of FIG. 1, in accordance with an illustrative embodiment of the present disclosure. As shown in FIGS. 2A-C, the injector head assembly 102 may include a pair of gearbox units 202A, 202B, each coupled to a corresponding gripper/chain assembly 204A, 204B, respectively. In certain implementations, the gearbox units 202A, 202B may be a hydraulic drive gearbox unit. Accordingly, each gripper/chain assembly 204A, 204B may be driven by the corresponding gearbox unit 202A, 202B. The injector head assembly 102 may further include one or more traction cylinders 206 that operate to apply pressure to skid plates 208.

Turning now to FIG. 3A-C, the operation of the traction cylinders 206 and the skid plate 208 in accordance with an illustrative implementation of the present disclosure is disclosed in further detail. Specifically, FIG. 3A depicts a side close-up view of the injector head assembly 102 of FIG. 1 and FIGS. 2A-2C. FIG. 3B depicts a cross-sectional view of the injector head assembly 102 of FIG. 3A. Similarly, FIG. 3C depicts a cross-sectional view of the injector head assembly of FIG. 3A with one side of the crash frame 104 removed to show the components as they are configured therein.

As shown in FIG. 3A-C, each skid plate 208 is coupled to a bearing plate 212. The skid plates 208 and the bearing plates 212 may be made from any suitable material known to those of ordinary skill in the art. For instance, in certain illustrative embodiments, the skid plates 208 may be made from high grade aluminum and the bearing plates 212 may be made from hardened steel. The bearing plates 212 provide the wearing surface that is in contact with the roller bearings of the gripper/chain assembly 204, as discussed in more detail below.

FIG. 4 depicts a close-up view of one of a chain link of a gripper/chain assembly 204A, 204B which is denoted generally with reference numeral 400. In certain illustrative embodiments, the chain link 400 may consist of a roller bearing 402 on one side and a gripper 404 on the other side. As shown in FIG. 4, the roller bearing 402 may be disposed on the side opposite to the gripper 404.

Each gripper/chain assembly 204A, 204B may have a plurality of chain links 400 each having one or more roller bearings 402 and one or more grippers 404 as shown in FIG. 4. The grippers 404 are configured to engage a length of coil tubing running through the injector head assembly 102. In certain illustrative embodiments, each gripper 404 may be configured as a semi-cylinder shaped cut-out allowing the surface of the gripper 404 to engage a greater area of the coil tubing 110 and more evenly apply pressure to the coil tubing 110. The cut-out for a gripper 404 may be sized differently to engage with different sizes of coil tubing 110. As shown in FIGS. 3A-C and FIG. 4, the gripper 404 may be coupled to roller bearings 402, which in turn engage a bearing plate 212. The use of roller bearings 402 serves to reduce friction between the gripper/chain assembly 204A, 204B and the corresponding bearing plate 212 by allowing the roller bearings 402 to roll across the surface of the bearing plate 212. Multiple links in the gripper/chain assembly 204 may be coupled through chain links 400. This arrangement permits an operator to replace/repair either one gripper 404 at a time or to replace/repair the entire gripper/chain assembly 204A, 204B in one service operation. Replacing the entire gripper/chain assembly 204A, 204B in one operation ensures that all grippers 404 operate in a similar condition, i.e., a singular worn item does not get maintained with the system. This also allows service to be performed in a shorter amount of time.

Returning to FIGS. 3A-C, the bearing plates 212 which are coupled to corresponding skid plates 208 provide a wearing surface for rollers 402 on the gripper/chain assembly 204. The traction cylinders 206 provide the force to push and pull the skid plate 208 so as to engage the bearing plate 212 with the gripper/chain assembly 204. Accordingly, the traction cylinders 206 can move the skid plates 208, and in turn, the bearing plates 212, between different positions to apply more, or less pressure, on to the coil tubing 110. For instance, the traction cylinders 206 may move the skid plates 208 and the bearing plates 212 between a first position which is further from the coil tubing 110 being directed through the injector head assembly 102 and a second position which is closer to the coil tubing 110. Accordingly, this configuration of the bearing plates 212 provides for reduced friction under load and provides a means of controlling the pressure on each gripper 404 as it is engaged within the load cycle via the skid plate 208 and traction cylinders 206.

Specifically, FIG. 3B provides an illustration of the injector head assembly 102 focusing on the interaction of the skid plate 208, the bearing plate 212, and each gripper/chain assembly 204A and 204B. The operation of the injector head assembly 102 is now discussed in conjunction with one of the gripper/chain assemblies 204A. The other gripper/chain assembly 204B operates in the same manner. As shown in FIG. 3B, traction cylinders 206 apply pressure to the skid plate 208, which in turn applies pressure to the bearing plate 212. This brings the bearing plate 212 into contact with the gripper/chain assembly 204A, enabling the roller bearings 402 of the gripper/chain assembly 204A to roll across the surface of the bearing plate 212. Additionally, the pressure to the bearing plate 212 engages the grippers 404 of the gripper/chain assembly 204A with a length of coil tubing that is being directed between the two gripper chain assemblies 204A and 204B.

FIG. 3C is an illustration of an injector head assembly 102 focusing on the motion of each gripper/chain assembly 204A, 204B and the corresponding hydraulic drive gearbox unit 202A, 202B. As shown in FIG. 3C, each gripper/chain assembly 204A, 204B is coupled to a corresponding drive motor 205A, 205B which is driven by the gear box unit 202A, 202B. The drive motors 205A, 205B provide a counter rotation arrangement to direct the coil tubing 110 into the well (or to pull the coil tubing 110 out). Specifically, the drive motors 205A, 205B are configured to turn in opposite directions such that the two facing sides of the two gripper/chain assemblies 204A, 204B move in the same vertical direction, i.e., move up together or move down together. In this configuration, one or more grippers 404 from each gripper/chain assembly 204A, 204B is able to engage with a length of coil tubing 110 running between the two facing sides of the two gripper/chain assemblies 204A, 204B.

In operation, the traction cylinders 206 are pressured, moving the skid plates 208 towards the centrally located coil tubing 110 as it is passing through the gripper/chain assemblies 204A, 204B. Once the gripper/chain assemblies 204A, 204B engage with the coil tubing 110, a reaction force is applied back through the bearing plates 212 and the skid plates 208, thereby allowing a precise control of the position and load being applied to the coil tubing 110. This arrangement is replicated about the vertical centerline of the injector head assembly 102, allowing the gripper/chain assemblies 204A, 204B to encapsulate the coil tubing 110 and move the coil tubing 110 up or down as directed by the drive motors 205A, 205B. Accordingly, the traction cylinders 206 apply pressure to the skid plates 208, to bring the bearing plates 212 into contact with the gripper/chain assembly 204A, 204B so as to engage a coil tube 110.

In certain implementations, the skid plate 208, which may be manufactured from high grade aluminum, may be guided via slides which are disposed on the skid plate 208. In certain implementations, there may be four slides, one located at each corner of the skid plate 208. Composite bearings may be used to ensure that the skid plate 208 slides smoothly on the guides. The traction cylinders 206 provide the force to push and pull the skid plate 208. The skid plate 208 is of a robust design to minimize the amount of deflection it will experience under the load condition. Minimizing the distortion ensures that the bearing plate 212 provides a smooth and level surface on which the roller bearings 402 of the gripper/chain assembly 204 can run.

Returning now to FIGS. 2A-2C, the injector head assembly 102 may further include one or more tensioning cylinders 210. In certain implementations, the tensioning cylinders 210 may be disposed to apply a force in a direction that is substantially perpendicular to the direction of the force applied by the traction cylinders 206. The tensioning cylinders 210 are configured to apply sufficient force to ensure there is no chain ‘slap’ during operation. Specifically, the tensioning cylinders 210 are operable to maintain a desired degree of tension within the chain/gripper assembly 204. In certain implementations, the amount of force (pressure) applied to the traction cylinders 206 is proportional to the amount of grip force that will be exerted to the coil tubing 110.

In certain implementations, the traction cylinders 206 and the tensioning cylinders 210 are located or accessible from the outside of the injector head assembly 102. For instance, as shown in FIGS. 2A-C, the traction cylinders 206 and the tensioning cylinders 210 may be mounted to an outer side of the crash frame 104. Accordingly, a single cylinder (either traction cylinder 206 and/or tension cylinder 210) may be removed and disengaged from the skid plate 208 to allow for replacement and/or repair of the cylinder. The remaining cylinders will continue to operate. As a result, the operable items may be repaired/replaced insitu and the injector head assembly 102 can remain in position above the well while it is being serviced. Additionally, in a preferred embodiment, the cylinders may all be of the same specification, simplifying the replacement of any cylinder during maintenance.

Accordingly, the use of the roller bearings 402 which run against the bearing plate 212 under the load condition reduces the friction when operating under a load. Additionally, the interaction of the bearing plates 212 with the roller bearings 402 of the gripper/chain assembly 204 provides a means of controlling the pressure applied by each gripper/chain assembly 204A, 204B as it engages the coil tubing 110. Specifically, the applied pressure by each gripper/chain assembly 204 in a load cycle may be controlled by an operator using the traction cylinders 206 which apply pressure to the roller bearings 402 through the skid plates 208 and the bearing plates 212.

Moreover, the bearing plates 212 are sacrificial items given the arduous nature of coil tubing. The bearing plates 212 may be accessed from the front and rear of the injector head assembly 102 and they may be easily removed to the sides of the injector head assembly. Accordingly, the bearing plates 212 may be easily replaced and/or repaired in situ.

Additionally, the gripper/chain assemblies 204A, 204B (including the grippers 404 and the roller bearings 402) are highly loaded during service. Accordingly, in certain implementations, the vertical space may be maximized to allow additional gripper assemblies to be in the load path, thus reducing the load to individual grippers 404, which in turn extends the life of the injector head assembly 102. Further, the grippers 404 are an integral part of the gripper/chain assembly 204. Accordingly, in certain implementations, a gripper carrier allows individual replacement of grippers 404. In another embodiment, the whole gripper/chain assembly 204 may be replaced in one operation. This results in a quick service period to change gripper size (e.g., going from 1½″ to 2″) and ensures that all grippers operate in a similar condition, i.e., a singular worn item does not get maintained with the system. When the gripper/chain assembly 204 or the grippers 404 do become worn out, an effective replacement can be made in a short time period which may be in a matter of minutes. Operational time is typically of great importance when performing subterranean operations. Accordingly, the longer the machine can operate and maintain performance the better.

In certain embodiments, different components may be manufactured from high grade aluminum which is sufficiently strong while giving a reduced weight compared to steel (steel being roughly 2½ times the weight of aluminum). The benefit of reduced weight is the ease of handling during installation, making the operator's job easier and therefore more productive.

Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the present invention. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.

Claims

1. An injector head assembly comprising:

a first gripper assembly and a second gripper assembly, wherein each of the first and second gripper assemblies comprises one or more grippers and one or more roller bearings;

a first gearbox unit and a second gearbox unit, wherein the first gearbox unit drives the first gripper assembly and wherein the second gearbox unit drives the second gearbox assembly;

a traction cylinder;

a skid plate coupled to the traction cylinder, wherein the traction cylinder applies pressure to the skid plate;

a bearing plate coupled to the skid plate, wherein the bearing plate is in contact with the one or more roller bearings.

2. The injector head assembly of claim 1, wherein the pressure applied by the traction cylinder moves the skid plate and the bearing plate between a first position and a second position.

3. The injector head assembly of claim 1, wherein the skid plate is made from high grade aluminum.

4. The injector head assembly of claim 1, wherein the bearing plate is made from steel.

5. The injector head assembly of claim 1, further comprising a tensioning cylinder, wherein the tensioning cylinder is operable to apply a force in a direction that is substantially perpendicular to direction of a force applied by the traction cylinder.

6. The injector head assembly of claim 1, wherein the skid plate is guided via a plurality of slides, wherein the slides are disposed on the skid plate.

7. The injector head assembly of claim 1, wherein the skid plate is coupled to a plurality of traction cylinders.

8. The injector head assembly of claim 1, wherein the first gearbox unit drives the first gripper assembly in a first direction and wherein the second gearbox unit drives the second gearbox assembly in a second direction.

9. The injector head assembly of claim 8, wherein a side of the first gripper assembly faces a side of the second gripper assembly and wherein the facing sides of the first gripper assembly and the second gripper assembly move in same vertical direction.

10. A injector head assembly comprising:

a coil tube injector head, wherein the coil tube injector head comprises: a first gripper assembly and a second gripper assembly, wherein each of the first and second gripper assemblies comprise one or more grippers and one or more roller bearings; a first gearbox unit and a second gearbox unit, wherein the first gearbox unit drives the first gripper assembly and wherein the second gearbox unit drives the second gearbox assembly; a traction cylinder; a skid plate, wherein the traction cylinder provides pressure to the skid plate; a bearing plate, wherein the skid plate is coupled to the bearing plate and wherein the bearing plate is coupled to the one or more roller bearings; and

wherein the coil tube injector head controls the feedrate of a length of coil tubing into or out of a well hole.

11. The injector head assembly of claim 10, wherein the pressure applied by the traction cylinder moves the skid plate and the bearing plate between a first position and a second position.

12. The injector head assembly of claim 10, wherein the skid plate is made from high grade aluminum.

13. The injector head assembly of claim 10, wherein the bearing plate is made from steel.

14. The injector head assembly of claim 10, further comprising a tensioning cylinder, wherein the tensioning cylinder is operable to apply a force in a direction that is substantially perpendicular to direction of a force applied by the traction cylinder.

15. The injector head assembly of claim 10, wherein the skid plate is guided via a plurality of slides, wherein the slides are disposed on the skid plate.

16. The injector head assembly of claim 10, wherein the skid plate is coupled to a plurality of traction cylinders.

17. The injector head assembly of claim 10, wherein the first gearbox unit drives the first gripper assembly in a first direction and wherein the second gearbox unit drives the second gearbox assembly in a second direction.

18. The injector head assembly of claim 17, wherein a side of the first gripper assembly faces a side of the second gripper assembly and wherein the facing sides of the first gripper assembly and the second gripper assembly move in same vertical direction.