SYSTEMS AND METHODS FOR DEPLOYING TUBULAR CONDUITS AND TUBING

Abstract

A system is disclosed for deploying tubing disposed on a spool. In an embodiment, the system includes a tubing support trailer that further includes a towing hookup assembly configured to couple the system to a vehicle, a spool support frame coupled to the towing hookup assembly, and a tubing spool rotatably coupled to the spool support frame. In addition, the system includes a tubing straightener trailer pivotally coupled to the tubing support trailer. The tubing straightening trailer includes a cart having a longitudinal cart axis and including a plurality of wheels, and a tubing straightening assembly coupled to the cart. The tubing straightening assembly is configured to move laterally relative to the cart and the cart axis. The tubing straightening assembly includes a plurality of rollers configured to engage and reduce the curvature of the tubing paid out from the spool.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. provisional patent application Ser. No. 62/094,742 filed Dec. 19, 2014, and entitled “Systems and Methods for Deploying Tubular Conduits and Tubing,” which is hereby incorporated herein by reference in its entirety for all purposes.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

This disclosure generally relates to tubular conduits. More particular, this disclosure generally relates to apparatus and methods for deploying tubular conduits from a spool.

Tubular conduits (e.g., tubing and coiled tubing) are employed in many industrial applications such as, for example, the transport of fluids, and oil and gas drilling and production operations. In some applications, the tubular conduits are constructed from a continuous tube (rather than a plurality of flanged pipe segments connected together end-to-end) to reduce the number of attachment or connection points along the conduit, simplify the installation process, etc. These continuous tubing conduits are typically wound onto a spool facilitate ease of storage, transportation, and deployment.

BRIEF SUMMARY OF THE DISCLOSURE

Some embodiments disclosed herein are directed to a system for deploying tubing disposed on a spool. In an embodiment, the system includes a tubing support trailer including a towing hookup assembly configured to couple the system to a vehicle, a spool support frame coupled to the towing hookup assembly, and a tubing spool rotatably coupled to the spool support frame. In addition, the system includes a tubing straightener trailer pivotally coupled to the tubing support trailer. The tubing straightening trailer includes a cart having a longitudinal cart axis and including a plurality of wheels. In addition, the tubing straightener trailer includes a tubing straightening assembly coupled to the cart. The tubing straightening assembly is configured to move laterally relative to the cart and the cart axis. The tubing straightening assembly includes a plurality of rollers configured to engage and reduce the curvature of the tubing paid out from the spool.

Other embodiments disclosed herein are directed to a tubing straightener trailer for straightening tubing paid out from a spool. In an embodiment, the tubing straightener trailer includes a cart having a longitudinal cart axis and including a plurality of wheels. In addition, tubing straightener trailer includes a tubing straightening assembly coupled to the cart. The tubing straightening assembly is configured to move laterally relative to the cart and the cart axis. The tubing straightening assembly includes a plurality of rollers configured to engage and reduce the curvature of the tubing paid out from the spool.

Still other embodiments disclosed herein are directed to a method for deploying tubing disposed on a spool. In an embodiment, the method includes (a) feeding the tubing through a tubing straightening assembly, wherein the tubing straightening assembly is moveably coupled to a cart having a longitudinal cart axis. In addition, the method includes (b) engaging the tubing with a plurality of rollers mounted within the tubing straightening assembly during (a). Further, the method includes (c) reducing a curvature of the tubing with the tubing straightening assembly during (b) as the tubing is paid out from the spool and fed through the tubing straightening assembly. Still further, the method includes (d) moving the tubing straightening assembly laterally with respect to the cart axis relative to the cart during (b) and (c).

Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of exemplary embodiments, reference will now be made to the accompanying drawings in which:

FIG. 1 is a perspective view of an embodiment of a tubing transportation and deployment system in accordance with the principles disclosed herein;

FIG. 2 is a perspective view of the tubing straightener trailer of the system of FIG. 1;

FIG. 3 is a top view of the tubing straightener trailer of FIG. 2;

FIG. 4 is a perspective view of the cart of the tubing straightener trailer of FIG. 2;

FIG. 5 is a top view of a tubing roller mounted to the cart of FIG. 4;

FIG. 6 is a side view of the tubing straightener trailer of FIG. 2;

FIG. 7 is an enlarged partial perspective view of one side of the tubing straightener trailer of FIG. 2;

FIG. 8 is an enlarged partial perspective view of the opposite side of the tubing straightener trailer of FIG. 2;

FIG. 9 is an enlarged partial perspective view of the rear roller assembly of the tubing straightener trailer of FIG. 2;

FIG. 10 is an enlarged perspective view of one of the straightener rollers of the tubing straightener trailer of FIG. 2;

FIG. 11 is an enlarged partial perspective view of the tubing straightener trailer of FIG. 2;

FIG. 12 is a side view of the tubing straightener trailer of FIG. 2 schematically illustrating the path of the tubing paid out from the tubing spool through the tubing straightening assembly;

FIGS. 13A and 13B are sequential top views of the system of FIG. 1 illustrating the tubing being paid out from the tubing spool;

FIG. 14 is an enlarged partial perspective view of one of the universal joints coupling the tubing support trailer and the tubing straightener trailer of FIG. 1;

FIG. 15 is a schematic side view of an alternative arrangement for the tubing roller of FIG. 5;

FIG. 16 is a side view of an embodiment of a tubing straightener trailer for use in the system of FIG. 1;

FIG. 17 is a perspective view of the tubing straightening assembly of the tubing straightener trailer of FIG. 16;

FIG. 18 is a schematic side view of one of the traversing cars engaging with one of the traversing bars of the tubing straightening assembly of FIG. 17;

FIG. 19 is an enlarged side view of the tubing straightening assembly of FIG. 17;

FIG. 20 is a top view of one of the roller assembly of the tubing straightening assembly of FIG. 17;

FIG. 21 is a side view of the roller assembly of FIG. 20;

FIG. 22 is a top view of the outfeed alignment assembly of the tubing straightening assembly of FIG. 17; and

FIG. 23 is a side view of the tubing straightening assembly of FIG. 17 schematically illustrating the path of the tubing paid out from the tubing spool through the tubing straightening assembly.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following discussion is directed to various exemplary embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . . ” Also, the term “couple” or “couples” is 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 connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis.

As previously described, continuous tubular conduits, also referred to herein as “tubing,” are typically wound onto a spool to facilitate ease of storage, transportation, and deployment. In many cases, especially in the case of larger diameter and/or more rigid tubing, the winding of the tubing onto the spool imparts a continuous bend or curve into the tubing, which generally follows and conforms with the curvature of the spool onto which the tubing is wound. However, in many applications, it is preferred that the tubing be deployed and installed in a straight or linear fashion (i.e., without bends or curves). Consequently, in such applications it is necessary to reduce or eliminate any bends and curves in the tubing. Typically, straightening devices and operations for tubing requires the use of multiple pieces of relatively large equipment, which undesirably increases the footprint and number of processing steps to deploy and install the tubing. However, embodiments disclosed herein include systems and methods for simultaneously deploying and straightening continuous tubular conduits paid out from spools while minimizing the size and footprint of the associated equipment and operation.

Referring now to FIG. 1, an embodiment of a tubing transportation and deployment system 10 is shown. In this embodiment, system 10 includes a tubing support trailer 20 and a tubing straightener trailer 100 pivotably coupled to support trailer 20 with a pair of universal joints 50 (which will be described in more detail below).

Referring still to FIG. 1, in this embodiment, tubing support trailer 20 is similar to those available from Big Reel Services, Inc. located in Calgary, Alberta, Canada. In particular, in this embodiment, trailer 20 includes a first or front end 20a, a second or rear end 20b opposite front end 20a, a base frame or chassis 22, a pair of wheels 24 pivotably coupled to chassis 22 (note: only one wheel 24 is visible in FIG. 1), and a pair tubing spool support frames 26 mounted to chassis 22. Chassis 22 is generally U-shaped with a towing attachment or hookup assembly 30 disposed at front end 20a and a pair of frame members 23 extending from assembly 30 to rear end 20b. As a result, an opening or space 29 is formed between members 23. As will be described in more detail below, opening 29 is sized to receive a spool 21 of tubing (e.g., tubing 18 shown in FIGS. 13A and 13B). Hookup assembly 30 includes a towing adapter 32 configured to engage with a corresponding towing hitch (not shown) on a vehicle (e.g., truck, tractor, etc.) such that trailer 20 (and/or system 10) can be towed or pulled to a desired location.

Spool support frames 26 are positioned between rear end 20b and hookup assembly 30, each frame 26 being coupled to one of the frame members 23 (note: while only one of the frames 26 is visible in FIG. 1, it is to be understood that both frames 26 are configured the same). Each spool support frame 26 includes a vertical post member 27 extending upward from the corresponding frame member 23 and a spool shaft support saddle 25 supported by the upper end of the vertical framing member 27. Saddles 25 are generally aligned with one another across opening 29 such that a central shaft (not visible) extending through tubing spool 21 along a central axis of rotation 17 can be seated therein. Thus, during both transportation and deployment operations, tubing spool 21 is rotatably supported on support frames 26 through the engagement of the tubing spool shaft and saddles 25 such that spool 21 may rotate about axis 17.

Referring now to FIGS. 2 and 3, tubing straightener trailer 100 is configured to straighten tubing deployed or paid out from tubing spool 21 mounted to support trailer 20. In this embodiment, tubing straightener trailer 100 includes a base cart 110 and a tubing straightening assembly 150 moveably mounted to cart 110.

Referring now to FIGS. 2-4, cart 110 provides a platform for supporting and transporting tubing straightening assembly 150 during deployment operations. Cart 110 has a central or longitudinal axis 105, a first or front end 110a, and a second or rear end 110b opposite front end 110a. In addition, cart 110 includes a base frame or chassis 112, a first pair of wheels 111 rotatably mounted to chassis 112 at front end 110a, and a second pair of wheels 113 rotatably mounted to chassis 112 at rear end 110b. Chassis 112 is generally rectangular in shape and includes a pair of parallel frame members 114 extending axially between ends 110a, 110b. Each frame member 114 includes an angled or bent portion 116 proximate front end 110a such that each member 114 includes a first or front second 115 extending axially from front end 110a to bent portion 116 and a second or rear section 117 extending axially from bent portion 116 to rear end 110b. As best shown in FIG. 4, due to the shape and orientation of bent portion 116, front portion 115 is vertically elevated relative to rear portion 117. A plurality of generally radially (or laterally) extending support members 118A, 118B, 118C span between frame members 114 to provide rigidity and support to cart 110. In particular, a first or front support member 118A extends between front sections 115, a second or mid support member 118B extends between members 114 at or proximate to the junction of rear sections 117 and bent portions 116, and a third or rear support member 118C extends between rear sections 117 at rear end 110b. In addition, a pair of support plates 119 extend between rear sections 117 of members 114. Still further, a plurality of traversing bars 120A, 120B, 120C extend between rear sections 117 of frame members 114 to provide a track for mounting pipe straightening assembly 150 to cart 110. A first or front traversing bar 120A extends between rear sections 117 proximate bent portion 116, a second or rear traversing bar 120B extends between members 114 at rear end 110b, and a third or mid traversing bar 120C extends between sections 117 axially between front and rear traversing bars 120A, 120B, respectively.

Referring now to FIGS. 2-5, a roller support bar 124 having a central axis 115 extends between front sections 115 of frame members 114, proximate front end 110a. A chassis roller 126 is slidably mounted to bar 124 such that roller 126 is free to rotate about axis 125 and traverse axially along bar 124 relative to axis 125. As is best shown in FIG. 5, roller 126 is a hollow tubular member having a first end 126a, a second end 126b opposite first end 126a, a throughbore 128 extending axially (relative to axis 125) between ends 126a, 126b, and a radially outer surface 123 extending between ends 126a, 126b. Outer surface 123 includes a first frustoconical section 127 extending axially from first end 126a and a second frustoconical section 129 extending axially from second end 126b to first frustoconical section 127. Outer surface 123 tapers radially inward toward axis 125 moving from each end 126a, 126b along each section 127, 129, respectively. Thus, outer surface 123 is oriented at an acute angle θ along each section 127, 129. In this embodiment the angle θ preferably ranges between 0° and 90°. As will be described in more detail below, frustoconical sections 127, 128 of outer surface 123 allow tubing paid out from spool 21 (see FIG. 1) to be guided onto and retained on roller 126.

As previously described, trailers 20, 100 are pivotably coupled to one another at a pair of universal joints 50. Referring now to FIGS. 1 and 14, one universal joint 50 is shown, it being understood that the other joint 50 is the same. In this embodiment, universal joint 50 includes a plurality of rigid coupling members 52, 54, 56 pivotably coupled to each other and to trailers 20, 100 to allow tubing straightener trailer 100 to pivot along multiple directions relative to tubing support trailer 20 during transportation and deployment operations. In particular, joint 50 includes a first coupling member 52 pivotably coupled to tubing straightening trailer 100, a second coupling member 56 pivotably coupled to tubing support trailer 20, and a third coupling member 54 pivotably coupled to each of the first and second coupling members 52, 56. First coupling member 52 includes a first end 52a and a second end 52b opposite first end 52a. First end 52a is pivotably coupled to front section 115 of one frame member 114 with a pair of connection flanges 51 such that member 52 may pivot relative to tubing straightening trailer 100 about a vertical axis 47. Second coupling member 56 includes a first end 56a and a second end 56b opposite first end 56a. Second end 56b is pivotably coupled one frame member 23 at rear end 20b of tubing support trailer 20 with a pair of connection flanges 27 such that member 56 may pivot relative to support trailer 20 about a vertical axis 59 (i.e., parallel to and radially offset from first axis 47). Third coupling member 54 includes a first end 54a, a second end 54b opposite first end 54a, a first pair of connection flanges 53 extending from first end 54a, and a second pair of connection flanges 58 extending from second end 54b. Second end 52b of first coupling member 52 is pivotably coupled between flanges 53 on first end 54a of third coupling member 54 about a horizontal axis 55 (i.e., oriented at 90° relative to vertical axes 47, 59 previously described). First end 56a of second coupling member 56 is pivotably coupled between flanges 27 on second end 54b of third coupling member 56 about a horizontal axis 57 (i.e., axis 57 is parallel to and radially offset from axis 55). Thus, third coupling member 56 may pivot about axes 55, 57 relative to first and second coupling members 54, 56, respectively. As a result, all movement (e.g., rotation) of tubing support trailer 20 relative to tubing straightening trailer 100 is accommodated by universal joint 50. Specifically, any rotation of trailer 20 relative to trailer 100 along a vertically oriented axis is accommodated by rotation of member 52 relative to trailer 100 about axis 47 and rotation of member 56 relative to trailer 20 about axis 59. Additionally, any rotation of trailer 20 relative to trailer 100 along a horizontally oriented axis, and any vertical movement of trailer 20 relative to trailer 100 is accommodated by rotation of member 54 relative to members 52, 56 about axes 55, 57, respectively.

Referring now to FIGS. 3 and 6-8, tubing straightening assembly 150 receives tubing paid out from spool 21 (see FIG. 1) and straightens the tubing to a desired curvature depending on the specific application. In this embodiment, straightening assembly 150 includes a base or deck 152 coupled to cart 110, a mounting plate 180 extending vertically upward from deck 152, and a plurality of straightening roller assemblies 190, 200, 220 having rollers configured to engage with and straighten the tubing paid out from spool 21 during deployment operations.

Deck 152 has a longitudinal axis 155, a first or front end 152a, a second or rear end 152b opposite front end 152a, a top side 151, a bottom side 153 radially opposite top side 151, a first lateral side 157, and a second lateral side 159 radially opposite first lateral side 157 with respect to axis 155. Deck 152 is mounted to cart 110 such that axis 155 of deck 152 is generally parallel to axis 105 (but axes 152, 105 may be radially offset from one another depending on the precise position of deck 152 along cart 110), front end 152a is proximate front end 110a of cart 110 and rear end 152b is proximate rear end 110b of cart 110. In addition, deck 152 is mounted to cart 110 such that it may freely traverse laterally relative to cart 110. In particular, a first or front roller assembly 154 is mounted to bottom side 153 at front end 152a and a second or rear roller assembly 156 is mounted to bottom side 153 at rear end 152b. Front roller assembly 154 engages front traversing bar 120A with a plurality of rollers and rear roller assembly 156 engages rear traversing bar 120B with a plurality of rollers. Each roller assembly 154, 156 is configured the same; and thus, only the details of rear roller assembly 156 will be described below, it being understood that front roller assembly 154 is the same.

Referring now to FIGS. 3 and 7-9, rear roller assembly 156 includes one or more coupling flanges 160 extending from bottom side 153 of deck 152 at rear end 152b. Coupling flanges 160 rotatably support a first plurality of traversing rollers 162 on first lateral side 157 of deck 152 and a second plurality of traversing rollers 164 on second lateral side 159. A plurality of covers or shields 166 are coupled to coupling flanges 160 such that each shield 166 covers one of the rollers 162 or one of the rollers 164.

As is best shown in FIGS. 8 and 9, in this embodiment, the first plurality of traversing rollers 162 includes a total of three (3) rollers 162—with one of the rollers 162 engaging the top of rear traversing bar 120B, a second of the rollers 162 engaging the bottom of bar 120B, and a third of the rollers 162 engaging a side of bar 120B. While not specifically shown, it should be appreciated that second plurality of traversing rollers 164 similarly includes a total of three (3) rollers 164—with one of the rollers 164 engaging the top of rear traversing bar 120B, a second of the rollers 164 engaging the bottom of bar 120B, and a third of the rollers 164 engaging the side of bar 120B. Thus, the engagement of rollers (e.g., rollers 162, 164) of front roller assembly 154 with front traversing bar 120A and the engagement of rollers (e.g., rollers 162, 164) of rear roller assembly 156 with rear traversing bar 120B allows deck 152 (and thus tubing straightening assembly 150) to traverse in a lateral direction represented by arrow A in FIG. 3 that is oriented 90° relative to axes 105, 155 in top view. As will be described in more detail below, movement of straightening assembly 150 along direction A (FIG. 3) allows assembly 150 to receive and straighten tubing (e.g., tubing 18 shown in FIGS. 13A and 13B) paid out from tubing spool 21 (see FIG. 1) while reducing the risk of bending or kinking the same during deployment operations.

Referring now to FIGS. 6 and 7, a leading roller 192 is disposed on top side 151 of deck 152 at front end 152a. As will be described in more detail below, leading roller 192 guides tubing from chassis roller 126 toward the roller assemblies of tubing straightening assembly 150. In this embodiment, leading roller 192 is rotatably mounted to a shaft 191 that extends between a support plate 193 mounted to top side 151 of deck 152 and mounting plate 180. As shown, shaft 191 extends between plates 193, 180 along a direction that is parallel to and radially offset from axis 125. In addition, roller 192 is shaped in a substantially similar manner to roller 126 previously described. Thus, roller 192 has an outer surface that includes a pair of frustoconical surfaces that taper inward toward each other (e.g., at angle θ) from the outer ends in order to guide and retain tubing paid out from spool 21 during operations in the same manner as described above for roller 126.

Referring still to FIGS. 6 and 7, a winch assembly 170 is mounted to deck 152 at front end 152a. As will be described in more detail below, winch assembly 170 provides a powered mechanism for pulling the leading end of tubing paid out from spool 21 (FIG. 1) through tubing straightening assembly 150. In this embodiment, winch assembly 170 includes a winch 172 that is mounted to a winch support plate 174 extending axially from front end 152a of deck 152 with respect to axis 155. A winch cable guide 167 is mounted at rear end 152b of deck 152 and includes a pair of guide wheels 169A, 169B rotatably mounted between a pair of support plates 168. In particular, winch cable guide 167 includes a first or upper guide wheel 169A proximate top side 151 and a second or lower guide wheel 169B proximate bottom side 153. As will be described in more detail below, during deployment operations, to initiate the feed of tubing from spool 21 (FIG. 1) through straightening assembly 150, a winch cable (not shown) is fed between deck 152 and cart 110 from winch 172 and is guided over guide wheels 169A, 169B. Thereafter, the winch cable is routed through straightening assembly 150 toward spool 21 where is it coupled to a leading end of the tubing disposed thereon. As a result, subsequent actuation of winch 172 to retract the winch cable allows the tubing to be initially fed through the tubing straightening assembly 150.

Referring now to FIGS. 6-8, mounting plate 180 is coupled to first lateral side 157 of deck 152, and extends vertically upward from top side 151. In addition, mounting plate 180 includes a first or front end 180a that is proximate front end 152a on deck 152 and a second or rear end 180b that is proximate rear end 152b. As previously described above, mounting plate 180 and deck 152 support a plurality straightening roller assemblies for engaging with and straightening tubing paid out from spool 21 (FIG. 1) during deployment operations. In particular, in this embodiment, a total of three (3) roller assemblies are mounted on or proximate mounting plate 180—a first or front roller assembly 190 proximate front end 180a, a second or rear roller assembly 220 that is proximate rear end 180b, and a third or mid roller assembly 200 that is axially disposed between rollers assemblies 190, 220, with respect to axes 155, 105.

Referring still to FIGS. 6-8, front roller assembly 190 includes a first straightening roller 250A rotatably disposed on a shaft 195 mounted to a bracket 196 that is fixably mounted to plate 180 proximate front end 180a. Referring briefly to FIG. 10, roller 250A will be described it being understood that rollers 250B, 250C, 250D, 250E are the same. Roller 250A includes a central or longitudinal axis 255, a first end 252, a second end 254 opposite front end 252, a radially outer surface 256 extending axially between ends 252, 254, and a throughbore 258 also extending axially between ends 252, 254. Radially outer surface 256 includes a first cylindrical surface 257 extending axially from first end 252, a second cylindrical surface 259 extending axially from second end 254, and an annular recess 253 extending axially between surfaces 257, 259 and radially inward (e.g., toroidally) from surfaces 257, 259. During deployment and straightening operations, tubing paid out from spool 21 (see FIG. 1) engages with radially outer surface 256 of roller 250A such that the tubing is substantially seated within recess 253. As a result, in at least some embodiments, recess 253 may be formed to correspond with the outer curvature of the tubing being straightened; however, such correspondence is not required. Referring again now to FIGS. 6-8, roller 250A is mounted to shaft 195 on bracket 196 such that shaft 195 is aligned with axis 255 (see FIG. 9) and axis 255 extending parallel to and radially offset from axis 125 of bar 124.

Front roller assembly 190 also includes a second straightening roller 250B rotatably mounted to a shaft 199 that is coupled to a pivot arm 198. As previously described, roller 250B is the same as roller 250A. It should also be appreciated that when roller 250B is installed on shaft 199, axis 255 of roller 250B is substantially aligned with shaft 199 and is oriented parallel to and radially offset from axis 255 of roller 250A.

As is best shown in FIG. 6, pivot arm 198 is an elongate member that includes a first end 198a and a second end 198b opposite first end 198a. Shaft 199 is mounted to first end 198a while second end 198b is pivotably mounted to deck 152 such that arm 198 and roller 250B may rotate about end 198b during operations. As will be appreciated by one of ordinary skill in the art, such rotation of arm 198 about end 198b results in a vertical height adjustment for roller 250B relative to deck 152. A linear actuator 194, which in this embodiment is a hydraulic cylinder, is coupled to pivot arm 198 between ends 198a, 198b. Actuator 194 includes a central longitudinal axis 197, a first end 194a, and a second end 194b opposite first end 194a. First end 197a is pivotably coupled to pivot arm 198 while second end 194b is pivotably mounted to deck 152. During operations, actuator 194 is actuated to extend and/or retract ends 194a, 194b apart and/or away from each other, respectively, in order to induce rotation of pivot arm 198 about second end 198b and thereby adjust the vertical height of roller 250B relative to deck 152 as previously described.

Referring still to FIGS. 6-8, mid roller assembly 200 includes a third straightening roller 250C and a fourth straightening roller 250D arranged axially adjacent one another with respect to the axes 105, 155. As previously described, each of the third and fourth straightening rollers 250C, 250D, respectively, are the same as roller 250A. As is best shown in FIG. 7, each roller 250C, 250D is rotatably mounted to a respective shaft 202 depending from one of a pair of support blocks 204, each support block 204 being disposed on a pair of respective tie rods 206 that extend vertically between a pair of vertically opposing mounting brackets 208 mounted to plate 180. In this embodiment, one of the pair of rods 206 extending through each block 204 is threaded along its entire length (e.g., with Acme threads) while the other one of the pair of rods 206 extending through each block 204 is smooth (note: the threaded rod 206 for each block 204 is designated in the Figures and herein as 206′ and the smooth rod 206 for each block 204 is designated in the Figures and herein as 206″). In addition, each threaded rod 206′ is threadably received through the corresponding block 204 and each smooth rod 206″ is slidably received through the corresponding block 204. Thus, the vertical positions of rollers 250C, 250D relative to deck 152 may be adjusted through rotation of the threaded rods 206′, thereby causing threaded engagement between rods 206′ and the corresponding block 204, and sliding engagement between rods 206″ and the corresponding block 204. In addition, when each of the rollers 250C, 250D are installed on the respective shafts 202, axes 255 of rollers 250C, 250D are substantially aligned with shafts 202 and are each oriented parallel to and radially offset from axes 255 of roller 250A, 250B, and axis 125 of bar 124.

Referring now to FIGS. 6-8 and 11, rear roller assembly 220 includes a fifth straightening roller 250E arranged proximate rear end 180b of plate 180. As previously described, fifth roller 250E is the same as roller 250A previously described. As is best shown in FIGS. 6 and 7, roller 250E is rotatably mounted to a shaft 222 depending from a support block 224, which is slidably disposed on a pair of tie rods 226 that extend vertically between a pair of vertically opposing mounting brackets 228 mounted to plate 180. In addition, a vertically extending transfer member 223 is coupled to block 224 and extends vertically through a corresponding aperture 219 in the uppermost mounting bracket 228. During operations, roller 250E may traverse along tie rods 226 through sliding engagement between rods 226 and block 224 in a manner similar to that described above for blocks 204 supporting rollers 250C, 250D. It should be appreciated from FIGS. 6 and 7, when roller 250E is installed on shafts 222, axis 255 of rollers 250E is substantially aligned with shaft 222 and is oriented parallel to and radially offset from axes 255 of roller 250A, 250B, 250C, 250D and axis 125 of bar 124.

Referring now to FIGS. 6-8 and 11, transfer member 223 includes a first or upper end 223a, and a second of lower end 223b opposite upper end 223a. Upper end 223a includes a connection flange 221 that extends through a slot 227 in plate 180, while lower end 223b is coupled (e.g., mounted) to support block 224. A linear actuator 229 (e.g., a hydraulic cylinder) is disposed on an opposing side of plate 180 from roller 250E and includes a central or longitudinal axis 225 that is generally vertically oriented and is parallel to and radially offset from tie rods 226, a first or upper end 229a, and a second or lower end 229 opposite upper end 229a along axis 225. Upper end 229a is pivotably coupled to connection flange 221 of transfer member 223 and lower end 229b is pivotably coupled to plate 180. During operations, actuator 229 is actuated to extend and/or retract ends 229a, 229b apart and/or away from each other along axis 225, respectively, in order to raise and/or lower roller 250E along tie rods 226 between brackets 228 as previously described.

Referring now to FIGS. 1, 6, and 12, during deployment operations, tubing wound on spool 21 is paid out toward chassis roller 124, is fed toward leading roller 192, and then is routed into straightening roller assemblies 190, 200, 220 in tubing straightening assembly 150 to remove a desired amount of the curvature or bend in the tubing resulting from being previously wound on spool 21. In particular, to initiate these deployment operations, the winch cable (not shown) of winching assembly 170 is fed between deck 152 and cart 110 from winch 172, guided over guide wheels 169A, 169B, and fed through straightening assembly 150 such that it may then be secured to a leading end of the tubing on spool 21, in the manner previously described. Thereafter, winch 172 is actuated to retract the winch cable, and thus, pulls the leading end of the tubing through straightening assembly 150. In particular, as is best shown in FIG. 12 (where the path of the tubing through straightening assembly 150 is generally schematically indicated with arrows 275), tubing is routed over leading roller 192, between first and second straightening rollers 250A, 250B, under third and fourth straightening rollers 250C, 250D, and finally over fifth straightening roller 250E. As a result, as tubing is routed between and around rollers 250A, 250B, 250C, 250D, 250E as described above, it is effectively bent in alternating directions (e.g., upward and downward), which removes (or lessens) the original bend or curvature caused by winding tubing on spool 21 such that the tubing may be substantially straight after engaging with roller 250E. Upon exiting straightening assembly 150 (i.e., at rear end 110b of cart), the now substantially straightened tubing is connected to another component (e.g., pipeline, well, etc.), such that additional tubing may be paid out from spool 21 and fed through straightening assembly 150 by simply moving (e.g., towing) tubing transportation and deployment system 10 (e.g., tubing support trailer 20 and tubing straightening trailer 100) along the desired path (e.g., with a vehicle coupled to cowing coupler 32) for tubing. Alternatively, in some embodiments, upon exiting straightening assembly 150 a separate machine or vehicle (e.g., an excavator) is used to pull the leading end of the tubing from spool 21 and through straightening assembly 150.

To facilitate appropriate contact between the tubing and rollers 250A, 250B, 250C, 250D, 250E during the above described straightening operations, the height of second roller 250B is adjusted through actuation of actuator 194, the vertical heights of rollers 250C, 250D are adjusted along tie rods 206 through rotation of threaded rods 206′ extending through blocks 204, and the vertical height of roller 250E is adjusted through actuation of actuator 229, all in the manner described above. Specifically, actuator 194 is extended/retracted along axis 197 to ensure that tubing fed from spool 21 is engaged between rollers 250A, 250B. In addition, the vertical position of rollers 250C, 250D is set along tie rods 206 in the manner previously described prior to the initiation of deployment operations to ensure adequate contact between the tubing and rollers 250C, 250D. The pre-set vertical positions of rollers 250C, 250D is influenced by a variety of factors such as, for example, the desired final bend in the tubing (if any), the size (e.g., outer diameter) of the tubing, the rigidity of the tubing, etc. Further, actuator 229 is extended/retracted along axis 225 to achieve a desired level of contact/bending of the tubing as it moves over top of roller 250E. The vertical height of roller 250E and the level of contact/bending of tubing over roller 250E has a notable influence in the resulting straightness of the tubing upon exiting straightening assembly 150. Specifically, in this embodiment, as the vertical separation between the positions of rollers 250C, 250D and roller 250E increases, the amount of bend/curve in the deployed tubing also increases and as the vertical separation between the positions of rollers 250C, 250D and roller 250E decreases, the amount of bend/curve in the deployed tubing also decreases.

Referring now to FIGS. 13A and 13B, as tubing 18 is paid out from spool 21 and spool 21 is rotated about axis 17 in the manner described above, a payout point 19, where the tubing 18 leaves spool 21, traverses axially back and forth with respect to axis 17. Specifically, the progression from FIG. 13A to 13B shows payout point 19 for tubing 18 shifting axially along spool 21 with respect to axis 17. For larger and more rigid tubing, there is an increased risk of kinking or unwanted lateral bending when the position of straightening assembly 150 is greatly separated from point 19 along the axial or lateral direction (e.g., along direction A, axis 17, etc.). As a result, as is shown in FIGS. 13A and 13B, in this embodiment, during deployment operations, straightening assembly 150 is allowed to traverse laterally along direction A relative to cart 110 such that payout point 19 is always generally aligned with tubing straightening assembly 150. It should be appreciated that in at least some embodiments, straightening assembly 150 slightly lags behind payout point 19 along axis 17 due to the balance of forces within system 10; however, this slight difference in position during deployment operations is small enough so as not to cause kinking or bending of tubing 18 in the lateral direction (e.g., axis 17, direction A, etc.). As previously described above, the lateral movement of straightening assembly 150 along direction A relative to cart 110 is facilitated through engagement of rollers (e.g., rollers 162, 164) of roller assemblies 154, 156 along front and rear transfer bars 120A, 120B, respectively (FIGS. 8 and 9). Moreover, in this embodiment, since chassis roller 126 is slidably engaged with bar 124, during the above described movement of point 19 and assembly 150, roller 126 also traverses laterally (e.g., along direction A) with respect to cart 110 to further facilitate guiding of tubing 18 from spool 21 to straightening assembly 150.

In this embodiment, traversal or movement of assembly 150 along direction A is driven or caused by the movement of payout point 19, such that assembly 150 passively follows (or is pulled) along direction A by tubing. However, it should be appreciated that in other embodiments, assembly 150 is independently driven along direction A independent of the influence by tubing 18 (e.g., with a motor or other actuator). Specifically, in some embodiments, assembly 150 is driven along direction A with one of more hydraulic cylinders mounted between cart 110 and assembly 150.

Referring now to FIG. 16, an embodiment of a tubing straightener trailer 300 is shown. Trailer 300 can be used in place of trailer 100 within the tubing transportation and deployment system 10. Tubing straightener trailer 300 is configured to straighten tubing deployed or paid out from the tubing spool 21 mounted to support trailer 20 as previously described and shown in FIG. 1. In this embodiment, tubing straightener trailer 300 includes a base cart 310, a base frame 352 mounted to cart 310, and a tubing straightening assembly 350 moveably coupled to cart 310 via the base frame 352. In other words, the base frame 352 attaches the tubing straightening assembly 350 to cart 310.

Cart 310 provides a platform for supporting and transporting tubing straightening assembly 350 during deployment operations. Cart 310 has a central or longitudinal axis 315, a first or front end 310a, and a second or rear end 310b opposite front end 310a. In addition, cart 310 includes a bed or base 312, a first or front axle assembly 314 mounted to base 312 at front end 310a, a second or rear axle assembly 316 mounted to base 312 at rear end 310b, a first pair of wheels 311 rotatably mounted to front axle assembly 314, and a second pair of wheels 313 rotatably mounted to rear axle assembly 316. In this embodiment, base 312 is generally rectangular in shape and includes an upper support surface 318 extending axially between ends 110a, 110b. While not specifically shown, in this embodiment, front end 310a includes connection members and/or structure to facilitate coupling of tubing straightening trailer 300 to tubing support trailer 120 in the same manner as described above for tubing straightening trailer 100 (see FIG. 1). In other embodiments, front end 310a of tubing straightening trailer 300 may include any suitable structure or assembly for coupling cart 310 to another component, such as, for example, a vehicle (e.g., truck, tractor, etc.) or another trailer (e.g., tubing support trailer 120).

Referring now to FIGS. 16 and 17, tubing straightening assembly 350 receives tubing paid out from spool 21 (see FIG. 1) and straightens the tubing to a desired curvature depending on the specific application. In this embodiment, straightening assembly 350 includes a roller support frame 380 moveably coupled to base frame 352, and a plurality of straightening roller assemblies 420, 430, 440 having rollers that engage and straighten the tubing paid out from spool 21 during deployment operations.

Referring still to FIGS. 16 and 17, base frame 352 includes a pair of laterally extending traversing bars 354A, 354B that are axially spaced from one another with respect to axis 315, and a pair of connecting members 359 coupled to and extending axially between traversing bars 354A, 354B with respect to axis 315. Thus, traversing bars 354A, 354B extend parallel to one another in the lateral or radial direction with respect to axis 315. Traversing bars include a first or front traversing bar 354A and a second or rear traversing bar 354B. As shown in FIG. 16, when base frame 352 is mounted to support surface 318, front traversing bar 354A is proximate front end 310a of cart 310 and rear traversing bar 354B is proximate rear end 310b of cart 310. In this embodiment, front and rear traversing bars 354A, 354B are I-beams that each include an upper flange 356 and a lower flange 358 vertically spaced from one another by a connecting member 357. Lower flanges 358 of traversing bars 354A, 354B engage with and are mounted to support surface 318 on cart 310 such that base frame 352 is secured to cart 310 during operations. As will be described in more detail below, upper flanges 356 of traversing bars 354A, 354B support roller support frame 380.

Roller support frame 380 is movably coupled to base frame 352 and is configured to support a plurality of roller assemblies 400, 420, 430, 440 for engaging with and straightening tubing as it is fed from spool 21 (see FIG. 1). Roller support frame 380 includes a central axis 385 that is parallel to and radially offset from axis 315 of cart 310, a first or front end 380a, and a second or rear end 380b opposite front end 380a. As shown in FIG. 16, when tubing straightening assembly 350 is mounted to cart 310, front end 380a is proximate front end 310a of cart 310, and rear end 380b is proximate rear end 310b of cart 310.

In addition, roller support frame 380 includes a pair of axially extending frame members 382 and a housing 381 mounted to and supported by frame members 382. Frame members 382 each extend axially between ends 380a, 380b and are spaced from one another in the lateral or radial direction with respect to axis 385. Housing 381 includes a plurality of vertical support members 384 coupled to and extending from frame members 382, and a pair of axially or horizontally extending support members 386 coupled to the frame members 382. Together, members 384, 386 of housing 381 define (at least partially) a space 383 that receives at least some of the roller assemblies 420, 430, 440 during deployment operations.

Referring now to FIGS. 17 and 18, roller support frame 380 is movably supported on base frame 352 with a pair of traversing carts 390A, 390B. In particular, roller support frame 380 is mounted on a first or front traversing cart 390a that is movably disposed on front traversing bar 354A, and roller frame 380 is mounted on a second or rear traversing cart 390B that is movably disposed on a rear traversing bar 354B.

Referring particularly now to FIG. 18, traversing carts 390A is shown. Although only one traversing cart 390A and associated traversing bar 354A is shown in FIG. 18, it should be appreciated that the other cart 390B and corresponding bar 354B, respectively, are the same.

As shown in FIG. 18, traversing cart 390A includes an upper support plate 392, a pair of frame members 394 extending from plate 392, and a roller support plate 396 extending between frame members 394 in a direction that is parallel to plate 392. Traversing cart 390A supports a plurality of roller assemblies 398 that engage with flange 356 of the corresponding traversing bar 354A to facilitate relative movement of cart 390A relative to traversing bar 354A. Specifically, roller support plate 396 supports a pair of roller assemblies 398, and one of the frame members 394 supports another pair of roller assemblies 398. Each roller assembly 398 includes a roller 399 rotatably mounted on a shaft 397. The shaft 397 and roller 399 of each assembly 398 are secured to the plate 396 or member 394 with a coupling member 393 which in this embodiment comprises a threaded nut that engages with threads on one end of shaft 397. In this embodiment, the rollers 399 of the roller assemblies 398 on roller support plate 396 engage with a pair of laterally extending side surfaces 356a on flange 356 and the rollers 399 of the roller assemblies 398 on the frame member 394 engage with a pair of laterally extending upper and lower surfaces 356b on flange 356. Thus, cart 390A may freely traverse in the lateral or radial directions with respect to axes 315, 385 (see FIGS. 16 and 17) through rolling engagement of the rollers 399 in assemblies 380 and the laterally extending surfaces 356a, 356b making up upper flange 356.

Referring again to FIG. 17, frame members 382 of roller support frame 380 are mounted and secured to upper support plates 392 of traversing carts 390A, 390B. Therefore, during operations, roller support frame 380 can freely traverse laterally or radially with respect to axes 315, 385 along traversing bars 354A, 354B to facilitate removal of tubing (e.g., tubing 18) from spool 21 (see e.g., FIGS. 13A and 13B), during operations.

Referring now to FIGS. 17 and 19, a pre-bend assembly 400 is coupled to front end 380a of roller support frame 380. Pre-bend assembly 400 is configured to receive tubing (e.g., tubing 18) from spool 21 (see FIG. 1) during operations and place an initial bend thereon to counteract any curvature of the tubing caused by its storage on spool 21. Pre-bend assembly 400 includes upper linkage assembly 410 and a lower linkage assembly 411, each assembly 410, 411 being coupled to both roller support frame 380 and to a linear actuator 418.

Upper linkage assembly 410 includes a first upper link 412 and a second upper link 414. First upper link 412 is pivotably coupled to roller support frame 380 via a sub-frame assembly 413 and second upper link 414 is pivotably coupled to first link 412. Specifically, first upper link 412 includes a first end 412a and a second end 412b opposite first end 412a. First upper link 412 is pivotably coupled to support assembly 413 at second end 412b, and a roller 450A is pivotably coupled to first upper link 412 at first end 412a. Roller 450 is the same as rollers 250A-250E, previously described above.

Second upper link 414 includes a first end 414a and a second end opposite first end 414b. First end 414a is pivotably coupled to first upper link 412 at a point along first upper link 412 between the first end 412a and the second end 412b. Second end 414b of second upper link 414 is pivotably coupled to linear actuator 418. Linear actuator 418, which in this embodiment is a hydraulic cylinder, includes a first end 418a and a second end 418b opposite first end 418a. First end 418a is pivotably coupled to second end 414a of second upper link 414 and second end 418b is pivotably coupled to a pair of the vertical support members 384 of housing 381 on frame 380. During operations, actuator 418 is actuated to extend or retract ends 418a, 418b apart or away from each other, respectively. Because of the pivotal connection of second upper link 414 to first upper link 412, when actuator 418 is actuated to extend ends 418a, 418b apart from one another, first upper link 412 is rotated about second end 412b in a first direction 401 shown in FIG. 19. Conversely when actuator 418 is actuated to retract ends 418a, 418b toward one another, first upper link 412 is rotated about second end 412b in a second direction 403 shown in FIG. 19 that is opposite first direction 401.

Lower linkage assembly 411 includes a lower link 416 comprising a first end 416a and a second end 416b opposite first end 416a. First end 416a is rotatable coupled to first end 418a of actuator 418 and second end 416b is pivotably coupled to frame members 382 of roller support frame 380. A roller 450B is also pivotably coupled to second end 416b of lower link 416. As previously described above for roller 450A, roller 450B is the same as rollers 250A-250E, previously described above. Because of the pivotable coupling between first end 416a of lower link 416 and second end 418b of actuator 418, when actuator 418 is actuated to extend ends 418a, 418b apart from one another, lower link 416 is rotated about second end 416b in a first direction 407 shown in FIG. 19. Conversely, when actuator 418 is actuated to retract ends 418a, 418b toward one another, lower link 416 is rotated about second end 416b is a second direction 409 shown in FIG. 19 that is opposite first direction 407.

As can be appreciated from FIG. 19, when actuator 418 is actuated to extend ends 418a, 418b apart from one another, rollers 450A, 450B on links 412, 416, respectively, are rotated away from one another (with roller 450A rotating about second end 412b of first upper link 412 in the first direction 401 and with roller 450B rotating about second end 416b of lower link 416 in the first direction 407). Conversely, as can also be appreciated from FIG. 19, when actuator 418 is actuated to retract ends 418a, 418b toward one another, rollers 450A, 450B on links 412, 416, respectively, are rotated toward one another (with roller 450A rotating about second end 412b of first upper link 412 in the second direction 403 and with roller 450B rotating about second end 416b of lower link 416 in the second direction 409).

Referring again to FIGS. 17 and 19, as previously described above, roller support frame 380 supports a plurality of roller assemblies 400, 420, 430, 440 for engaging with and straightening a tubing conduit as it is fed from spool 21 (see FIG. 1). Specifically, in this embodiment, roller support frame 380 supports a first or front roller assembly 420, a second or rear roller assembly 430, and a third or mid roller assembly 440. Front roller assembly 420 is coupled between frame members 382 and is axially adjacent front end 380a and pre-bend roller assembly 400. Rear roller assembly 430 is coupled between frame members 382 and is axially adjacent rear end 380b of frame 380. Mid roller assembly 440 is disposed within space 383 defined by housing 381 and is axially disposed between front and rear roller assemblies 420, 430, respectively.

Referring now to FIGS. 20 and 21, front roller assembly 420 is shown. While only a single roller assembly 420 is shown in FIGS. 20 and 21, it should be appreciated that the other roller assembly 430 is the same.

Roller assembly 420 includes a support frame 422 comprising a central axis 425 and a pair of support plates 421 that radially oppose one another across axis 425. Plates 421 are coupled to one another with a pair of connecting members 429. Axis 425 is parallel to and radially offset from axes 315, 385 when roller assemblies 420, 430 are mounted to frame 380 and frame 380 is coupled to cart 310 (see FIGS. 16 and 17). Each support plate 421 includes an axially extending slot 424 that includes a plurality of axially spaced recesses or notches 426 formed therein. Plates 421 are arranged within frame 422 such that slot 424 and notches 426 are radially and axially aligned with one another with respect to axis 425. Each roller assembly 420, 430 includes a roller 450C, 450F that is rotatably disposed on a corresponding shaft 428 that extends radially through each of the slots 424. As previously described above for rollers 450A, 450B, rollers 450C, 450F are the same as rollers 250A-250E, previously described above. As can be appreciated from FIGS. 20 and 21, the position of rollers 450C, 450F within the corresponding frames 422 is axially adjustable by seating shaft 426 within different axially aligned pairs of notches 426 along slots 424.

Referring now to FIGS. 19-21, frames 422 of roller assemblies 420, 430 are coupled to frame members 382 by inserting bolts 427 through radially aligned holes in plates 421 and frame members 382, and securing bolts 427 to frame members 382 and plates 421 with threaded nuts 427. However, it should be appreciated that frames 422 of roller assemblies 420, 430 may be coupled to frame members 382 in any other suitable fashion, such as, for example, by welding plates 421 to frame members 382.

Referring again to FIG. 19, mid roller assembly 440 includes a pair of rollers 450D, 450E, a rocker arm assembly 442, a pivoting arm 444, and a linear actuator 446. As previously described above for rollers 450A, 450B, 450C, 450F, rollers 450D, 450E are the same as rollers 250A-250E, previously described above, and thus, a detailed description of rollers 450D, 450E is omitted herein in the interests of brevity. Rocker arm assembly 442 includes a first end 442a, and a second end 442b opposite first end 442a. Roller 450D is pivotably mounted to rocker arm assembly 442 at first end 442a, and roller 450E is pivotably mounted to rocker arm assembly 442 at second end 442b. Pivoting arm 444 is an elongate member that includes a first end 444a, and a second end 444b opposite first end 444a. Second end 444b is pivotally coupled to support members 386 of housing 381, and first end 444a is pivotably coupled to rocket arm assembly 442 at a point between ends 442a, 442b. Linear actuator 446, which in this embodiment is a hydraulic cylinder, includes a first end 446a and a second end 446b opposite first end 446a. Second end 446b is pivotably coupled to support members 386 of housing 381, and first end 446a is pivotably coupled to rocker arm assembly 442 at the same point as the first end 444a of pivoting arm 444 (i.e., at a point on rocker arm assembly 442 between ends 442a, 442b).

During operations, actuator 446 is actuated to extend or retract ends 446a, 446b apart or away from each other, respectively. Specifically, when actuator 446 is actuated to extend ends 446a, 446b away from one another, both pivoting arm 444 and rocker arm assembly 422 are rotated about second end 444b of pivoting arm 444 in a first direction 443 shown in FIG. 19. Conversely, when actuator 446 is actuated to retract ends 446a, 446b toward one another, both pivoting arm 444 and rocker arm assembly 442 are rotated about second end 444b of pivoting arm 444 in a second direction 441 shown in FIG. 19 that is opposite first direction 443. Thus, as can be appreciated in FIG. 19, extension of the ends 446a, 446b of actuator 446 causes rocker arm assembly 422 and rollers 450D, 450E to traverse vertically downward and axially rearward with respect to axis 385 along an arcuate path defined by pivoting arm 444 (particular end 444a), and a retraction of ends 446a, 446b of actuator 446 causes rocker arm assembly 442 and rollers 450D, 450E to traverse both vertically upward and axially frontward with respect to axis 385 along an arcuate path defined by pivoting arm 444 (particularly end 444a).

Referring again to FIGS. 16 and 17, a winch assembly 460 is mounted to roller support frame 380 at rear end 380b. As will be described in more detail below, winch assembly 460 provides a powered mechanism for pulling the leading end of tubing from spool (FIG. 1) through tubing straightening assembly 350. In this embodiment, winch assembly 460 includes a winch 462 mounted to roller support frame 380 and guide boom 464 extending axially from roller support frame 380. Guide boom 464 is an elongate member that includes a first end 464a and a second end opposite first end 464a. First end 464a is coupled to roller support frame 380 and second end 464b is distal to roller support frame 380. Thus, first end 464a may be referred to herein as a proximate end 464a, and second end 464b may be referred to herein as a distal end 464b. Proximate end 464a (see FIG. 16) is pivotably coupled to roller support frame 380 such that boom 464 may be rotated about proximate end 464a relative to roller support frame 380 during operations. As a result, when winch assembly 460 is not needed (e.g., after the leading end of the tubing has been fed through tubing straightening assembly 350) boom 464 may be pivoted about proximate end 464a from the position shown in FIGS. 16 and 17 (which may be referred to herein as an operating position) to a stowed position (i.e., boom 464 may be pivoted about end 464a such that distal end 464b is rotated clockwise toward roller support frame 380 in the view shown in FIG. 16). Boom 464 may be secured in both the operating position and the stowed position by a pinned connection (e.g., by engaging a pin through appropriate apertures in frame 380). A guide wheel 466 is rotatably coupled to distal end 464b of guide boom 464 that is configured to guide a winch cable (not shown) during winching operations. More particularly, as will be described in more detail below, during deployment operations, to initiate the feed of tubing from spool 21 (FIG. 1) through straightening assembly 350, a winch cable (not shown) is fed from winch 462 and is guided over guide wheel 466 (in this embodiment, the winch cable may be fed through boom 464 as it is routed to wheel 466). Thereafter, the winch cable is routed through straightening assembly 350 toward spool 21 where is it coupled to a leading end of the tubing disposed thereon. As a result, subsequent actuation of winch 462 to retract the winch cable allows the tubing to be initially fed through the tubing straightening assembly 350.

Referring now to FIGS. 16, 17, and 22, an outfeed alignment assembly 480 is coupled to rear end 380b of roller support assembly 380 and aligns the tubing in the desired deployment direction relative to straightening assembly 350 during deployment operations. As is best shown in FIGS. 17 and 22, outfeed alignment assembly 480 includes a mounting plate 481 attached to rear end 380b of roller support frame 380 and a pair of vertically spaced housing plates 482 rotatably coupled to mounting plate 481 with a pin member 486 having a vertically oriented central axis 485. Plate 481 includes a recess 483 sized to allow tubing fed from spool 21 to extend therethrough during operations. In this embodiment, plates 482 each extend parallel to axis 385, and axis 485 is disposed within a plane (not shown) that extends perpendicularly to each of the axes 315, 385. A pair of guide rollers 484 are rotatably mounted vertically between plates 482 such that each guide roller 484 is parallel to and radially offset from axis 485 of pin 486.

As will be described in more detail below, during tubing straightening operations, tubing that has exited tubing straightening assembly 350 is directed through recess 483 in plate 381 and between plates 482 and finally between rollers 484. Thus, the rotational position of plates 482 about axis 485 can determine the final bend or orientation of the tubing as it exits tubing straightening assembly 350. Accordingly, outfeed alignment assembly 480 also includes a linear actuator 488 to control and maintain the exiting orientation of outfeed alignment assembly 480, and thus, also the tubing as it is fed from tubing straightening assembly 350 during operations. In particular, linear actuator 488, which comprises a hydraulic cylinder in this embodiment, has a first end 488a and a second end 488b opposite first end 488a. Second end 488b is pivotably coupled to mounting plate 481, and first end 488a is pivotably coupled to housing plates 482 at a point that is distal pin 486. During operations, actuator 488 is actuated to extend or retract ends 488a, 488b apart or away from each other, respectively. In particular, when actuator 488 is actuated to extend ends 488a, 488b away from one another, plates 482 are rotated about axis 485 of pin 486 in a first direction 487 shown in FIG. 22. Conversely, when actuator 488 is actuated to retract ends 488a, 488b toward one another, plates 482 are rotated about axis 485 of pin 486 in a second direction 489 shown in FIG. 22 that is opposite the first direction 487. Thus, actuation of linear actuator 488 to extend or retract ends 488a, 488b controls the final lateral bend or orientation of the tubing as it exits tubing straightening assembly 350.

Referring now to FIGS. 16, 17, and 23, during deployment operations, tubing wound on spool 21 (FIG. 1) is paid out and then is routed toward pre-bend roller assembly 400 and then into straightening roller assemblies 420, 430, 440 in tubing straightening assembly 350 to remove a desired amount of the curvature or bend in the tubing resulting from being previously wound on spool 21. In particular, to initiate these deployment operations, the winch cable (not shown) of winching assembly 460 is fed over guide wheel 466 and through straightening assembly 350 such that it may then be secured to a leading end of the tubing on spool 21 in the manner previously described. Thereafter, winch 462 is actuated to retract the winch cable, and thus, pull the leading end of the tubing through straightening assembly 350. As is best shown in FIG. 23 (where the path of the tubing through straightening assembly 350 is generally schematically indicated with arrows 490), tubing is routed between rollers 450A, 450B of pre-bend roller assembly 400, over roller 450C of front straightening roller assembly 420, under rollers 450D, 450E of mid straightening roller assembly 440, and finally over roller 450F of rear straightening roller assembly 430. As a result, as tubing is routed between and around rollers 450A, 450B, 450C, 450D, 450E, 450F as described above, it is effectively bent in alternating directions (e.g., upward and downward), which removes (or lessens) the original bend or curvature caused by winding tubing on spool 21 such that the tubing is straight or substantially straight after engaging with roller 450F. Upon exiting straightening assembly 350, the tubing is finally routed through outfeed alignment assembly 480, where a final, desired lateral bend (if any) is imparted on the tubing by the rollers 484 and linear actuator 488. Thereafter, the now substantially straightened tubing is connected to another component (e.g., pipeline, well, etc.), such that additional tubing may be paid out from spool 21 and fed through straightening assembly 350 by simply moving (e.g., towing) tubing transportation and deployment system 10 (e.g., tubing support trailer 20 and tubing straightening trailer 300) along the desired path (e.g., with a vehicle) for tubing. Alternatively, in some embodiments, upon exiting straightening assembly 350 a separate machine or vehicle (e.g., an excavator) is used to pull the leading end of the tubing from spool 21 and through straightening assembly 350.

To facilitate appropriate contact between the tubing and rollers 450A, 450B, 450C, 450D, 450E, 450F during the above described straightening operations, the positions of rollers 450A, 450B, 450C, 450D, 450E, 450F may be adjusted relative to frame 380. In particular, linear actuator 418 may be extended or retracted to move rollers 450A, 450B apart or together, respectively, as described above. In addition, the positions of rollers 450C, 450F of front and rear roller assemblies 420, 430, respectively, are axially adjusted by traversing the rollers 450C, 450F through the corresponding slots 424 in frames 422 and seating the shafts 428 carrying rollers 450C, 450F within aligned pairs of notches 426 formed in slots 424 as previously described. Further, linear actuator 446 is extended/retracted to adjust the positions of rollers 450D, 450E in mid-roller assembly 440 as previously described.

Referring particularly to FIG. 17, during these above described tubing deployment operations, as tubing 18 is paid out from spool 21 and spool 21 is rotated about axis 17 (see FIG. 1), roller support frame 380 of tubing straightening assembly 350 is free to traverse laterally along traversing bars 354A, 354B via the traversing carts 390A, 390B, respectively, as described above. Thus, roller assemblies 400, 420, 430, 440 and outfeed alignment assembly 480 of tubing straightening assembly 350 traverse freely in the lateral direction (e.g., direction A shown in FIGS. 13A, 13B) to maintain alignment between the roller assemblies 400, 420, 430, 440, and outfeed alignment assembly 480 with the payout point (e.g., payout point 19 shown in FIG. 13A, 13B) of tubing 18 as it reciprocates laterally across spool 21 (see FIG. 1) during tubing payout and deployment operations in the manner previously described above.

In the manner described herein, through use of a tubing transportation and deployment system in accordance with the principles disclosed herein (e.g., system 10), tubing (e.g., tubing 18) may be paid out from a spool (e.g., spool 21) and simultaneously straightened within a single deployment operation, thus greatly reducing the complexity and time required for such operations. In addition, through use of a tubing transportation and deployment system in accordance with the principles disclosed herein (e.g., system 10), undesired lateral kinking or bending of the tubing (e.g., tubing 18) as it is paid out from a spool (e.g., spool 21) is avoided through the lateral movement of the tubing straightening assembly (e.g., assemblies 150, 350).

While embodiments disclosed herein have shown the deck 152 to be mounted to front and rear transfer bars 120A, 120B with front and rear roller coupling assemblies 154, 156, respectively, it should be appreciated that in other embodiments, deck 152 may additionally or alternatively be coupled to mid transfer bar 120C with a roller assembly (e.g., assemblies 154, 156) in a similar manner while still complying with the principles disclosed herein. In addition, while the specific path (e.g., arrows 275) of tubing that is routed through tubing straightening assembly 150 is shown and described as extending under rollers 250C, 250D, and over roller 250E, it should be appreciated that the specific path taken by tubing through rollers 250A, 250B, 250C, 250D, 250E can be widely varied while still complying with the principles disclosed herein. For example, in some embodiments, tubing extends above and over rollers 250C, 250D and then under roller 250E. Further, it should be appreciated that the specific designs of rollers 126, 192, 250A-250E, 450A-450F can be varied while still complying with the principles disclosed herein. For example, while chassis roller 126 has been described as including a radially outer surface 123 having first and second frustoconical sections 127, 129, it should be appreciated that in other embodiments, as is shown in FIG. 15, outer surface 123 of roller 126 may include a pair of radial extensions 327, 329 defining a central guide region 330 for receiving tubing paid out from spool 21 during operations.

While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of this disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

Claims

1. A system for deploying tubing disposed on a spool, the system comprising:

a tubing support trailer including: a towing hookup assembly configured to couple the system to a vehicle; a spool support frame coupled to the towing hookup assembly; and a tubing spool rotatably coupled to the spool support frame;

a tubing straightener trailer pivotally coupled to the tubing support trailer, wherein the tubing straightening trailer includes: a cart having a longitudinal cart axis and including a plurality of wheels; a tubing straightening assembly coupled to the cart; wherein the tubing straightening assembly is configured to move laterally relative to the cart and the cart axis; wherein the tubing straightening assembly includes a plurality of rollers configured to engage and reduce the curvature of the tubing paid out from the spool.

2. The system of claim 1, wherein the cart includes a plurality of laterally extending transfer bars, wherein the tubing straightening assembly includes a deck having a plurality of roller coupling assemblies, and wherein each of the roller coupling assemblies includes a plurality of rollers configured to engage with one of the plurality of transfer bars to facilitate lateral movement of the tubing straightening assembly relative to cart.

3. The system of claim 1, wherein the cart includes a support surface and a base frame mounted to the support surface;

wherein the tubing straightener assembly further comprises a roller support frame movably mounted to the to the base frame;

wherein the tubing straightening assembly further comprises a traversing cart coupled to each of the roller support frame and the traversing bar; and

wherein the traversing car includes one or more roller assemblies that each include a roller that engages with the traversing bar to allow the traversing cart to move laterally along the traversing bar.

4. The system of claim 1, wherein the tubing straightening assembly further comprises:

a roller support frame including a first end and a second end opposite the first end of the roller support frame; and

a pre-bend roller assembly coupled to the first end of the roller support frame;

wherein the pre-bend roller assembly comprises: a first linkage including a first roller; and a second linkage including a second roller; wherein the first linkage an the second linkage are each coupled to a linear actuator; and wherein actuation of the linear actuator is configured to move the first roller and the second roller toward one another or to move the first roller and the second roller apart from one another.

5. The system of claim 4,

wherein the first linkage of the pre-bend roller assembly comprises: a first link including a first end and a second end; and a second link including a first end and a second end; wherein the first roller is disposed at the first end of the first link and the second end of the first link is pivotably coupled to the roller support frame; wherein the first end of the second link is pivotably coupled to the first link at a point between the first end of the first link and the second end of the first link and the second end of the second link is pivotably coupled to an end of the linear actuator;

wherein the second linkage of the pre-bend assembly comprises: a third link including a first end and a second end; wherein the first end of the third link is pivotably coupled to the end of the linear actuator; wherein the second end of the third link is pivotably coupled to the roller support frame; and wherein the second roller is disposed at the second end of the third link.

6. A tubing straightener trailer for straightening tubing paid out from a spool, the tubing straightener trailer comprising:

a cart having a longitudinal cart axis and including a plurality of wheels;

a tubing straightening assembly coupled to the cart;

wherein the tubing straightening assembly is configured to move laterally relative to the cart and the cart axis;

wherein the tubing straightening assembly includes a plurality of rollers configured to engage and reduce the curvature of the tubing paid out from the spool.

7. The tubing straightener trailer of claim 6, wherein the cart includes a plurality of laterally extending transfer bars, wherein the tubing straightening assembly includes a deck having a plurality of roller coupling assemblies, and wherein each of the roller coupling assemblies includes a plurality of rollers configured to engage with one of the plurality of transfer bars to facilitate lateral movement of the tubing straightening assembly relative to cart.

8. The tubing straightener trailer of claim 6,

wherein the cart includes a support surface and a base frame mounted to the support surface; and

wherein the tubing straightener assembly further comprises a roller support frame movably mounted to the to the base frame;

wherein the roller support frame is configured to move laterally relative to the base frame.

9. The tubing straightener trailer of claim 8, wherein the base frame includes a traversing bar extending laterally with respect to the cart axis;

wherein the tubing straightening assembly further comprises a traversing cart coupled to each of the roller support frame and the traversing bar;

wherein the traversing car includes one or more roller assemblies that each include a roller that engages with the traversing bar to allow the traversing cart to move laterally along the traversing bar.

10. The tubing straightener trailer of claim 6, wherein a position of at least some of the plurality of rollers of the tubing straightening assembly are adjustable relative to the tubing straightening assembly.

11. The tubing straightener trailer of claim 6, wherein the tubing straightening assembly further comprises:

a roller support frame including a first end and a second end opposite the first end of the roller support frame; and

a pre-bend roller assembly coupled to the first end of the roller support frame;

wherein the pre-bend roller assembly comprises: a first linkage including a first roller; and a second linkage including a second roller; wherein the first linkage an the second linkage are each coupled to a linear actuator; and wherein actuation of the linear actuator is configured to move the first roller and the second roller toward one another or to move the first roller and the second roller apart from one another.

12. The tubing straightener trailer of claim 11,

wherein the first linkage of the pre-bend roller assembly comprises: a first link including a first end and a second end; and a second link including a first end and a second end; wherein the first roller is disposed at the first end of the first link and the second end of the first link is pivotably coupled to the roller support frame; wherein the first end of the second link is pivotably coupled to the first link at a point between the first end of the first link and the second end of the first link and the second end of the second link is pivotably coupled to an end of the linear actuator;

wherein the second linkage of the pre-bend assembly comprises: a third link including a first end and a second end; wherein the first end of the third link is pivotably coupled to the end of the linear actuator; wherein the second end of the third link is pivotably coupled to the roller support frame; and wherein the second roller is disposed at the second end of the third link.

13. The tubing straightener trailer of claim 6, wherein the tubing straightening assembly further comprises:

a roller support frame including a central frame axis, a front end, and a rear end opposite the front end of the roller support frame;

a front roller assembly disposed proximate the front end of the roller support frame;

a rear roller assembly disposed proximate the rear end of the roller support frame; and

a mid-roller assembly disposed axially between the front roller assembly and the rear roller assembly with respect to the frame axis;

wherein a position of the mid-roller assembly is adjustable relative to the roller support frame.

14. The tubing straightener trailer of claim 13,

wherein plurality of rollers comprises a pair of rollers disposed within the mid-roller assembly;

wherein the mid-roller assembly further comprises: a rocker arm assembly pivotably supporting the pair of rollers of the plurality of rollers; a pivoting arm including a first end and a second end; and a linear actuator; wherein the first end of the pivoting arm is pivotably coupled to the rocker arm assembly and the second end of the pivoting arm is pivotably coupled to the roller support frame; and wherein the linear actuator is pivotably coupled to the rocker arm assembly and the roller support frame; wherein actuation of the linear actuator causes rocker assembly to move along an arcuate path.

15. The tubing straightener trailer of claim 13, wherein the tubing straightening assembly further comprises:

an outfeed alignment assembly pivotably coupled to the rear end of the roller support frame;

wherein the outfeed alignment assembly comprises: a pair of guide rollers that are pivotably mounted to the roller support frame and are configured to pivot about a pivot axis that is disposed within a plane that extends perpendicularly to the frame axis of the roller support frame; and a linear actuator configured to adjust a rotational position of the guide rollers about the pivot axis.

16. A method for deploying tubing disposed on a spool, the method comprising:

(a) feeding the tubing through a tubing straightening assembly, wherein the tubing straightening assembly is moveably coupled to a cart having a longitudinal cart axis;

(b) engaging the tubing with a plurality of rollers mounted within the tubing straightening assembly during (a);

(c) reducing a curvature of the tubing with the tubing straightening assembly during (b) as the tubing is paid out from the spool and fed through the tubing straightening assembly; and

(d) moving the tubing straightening assembly laterally with respect to the cart axis relative to the cart during (b) and (c).

17. The method of claim 16, further comprising:

(e) adjusting a position of one or more of the plurality of rollers relative to the tubing straightening assembly.

18. The method of claim 17, wherein (e) comprises actuating a linear actuator.

19. The method of claim 16, further comprising:

coupling a leading end of the tubing to a winch cable extending from a winch coupled to the tubing straightening assembly; and

actuating the winch to pull the leading end of the tubing through the tubing straightening assembly.

20. The method of claim 16, further comprising:

(e) coupling the cart to a tubing support trailer that includes a spool support frame;

(f) rotatably supporting the spool on the spool support frame;

(g) coupling the tubing support trailer to a vehicle;

(h) towing the tubing support trailer and the cart after (g); and

(i) feeding tubing from the spool through the tubing straightening assembly during (h);

wherein the moving in (b) is performed during (h) and (i).