HEAVY LOAD PIPE HANDLER APPARATUS

Abstract

Some embodiments of the present disclosure relate to pipe handling apparatus that comprise a base, an elongate door, a pipe carrier, a lift member and a pipe carrier extension. In some embodiments the pipe carrier extension is operatively coupled to the pipe carrier so that when in an extended position, the pipe carrier and the pipe carrier extension can cooperatively receive, support and move a length of two or more connected sections of pipe between a lower surface and an upper surface. Some embodiments of the present disclosure relate to a system that includes the pipe handling apparatus and a pipe rack system and a connection system, wherein the system is configured to connect two or more pipes together so that the apparatus can move a length of already connected two or more pipes between the lower surface and the upper surface.

Description

TECHNICAL FIELD

The present disclosure relates to pipe handler apparatus and methods of handling pipe. In particular, the apparatus and methods of the present disclosure may be used to move objects between an elevated platform and a surface below the elevated platform.

BACKGROUND

Pipe handling apparatus are known for moving a section of heavy pipe from a lower surface to an elevated surface and vice versa. Such heavy pipes are combined as constituent components of a string of pipe that are used in forming and completing an oil and/or gas well.

During drilling or completion operations, the pipe is moved in two ways: (i) vertically, between the lower surface, which is typically the ground or ground floor of a drilling rig or a completion rig, to an elevated operational floor upon the rig; and, (ii) rotationally, whereby the pipes move between a substantially-horizontal storage orientation to a substantially-vertical operational orientation, for insertion or extraction from the well below the operational floor of the rig.

In order to extend from the surface towards the bottom of the well below, multiple pipes are connected end-to-end to form a string of pipe (whether drill pipe or casing or the like). The pipes are connected together via threaded connections. For example, a first pipe can be held in a vertical position on an elevated operational floor. Next, a second pipe is elevated from the lower level, where the pipes are stored while not in use, up to the elevated operational floor. The second pipe is then positioned inline with and above the first pipe where pipe string assembly equipment-that is on or above the operation floor of the rig -rotates the second pipe to threadably connect to the first pipe. Then the first and second pipes are pushed into the well so that the second pipe occupies the previous position of the first pipe. Next, a third pipe is elevated from the lower level to be positioned inline with and above the second pipe so that the second and third pipe can be threadably connected together. These steps are repeated until enough pipes are connected to form a string of connected pipes that extends the desired distance into the well.

These heavy pipes can weight upwards of about 15,000 pounds (one pound is equivalent to about 0.453 kilograms). In addition to their weight, the heavy pipes are also long. For example, a section of Range 1 (R1) pipe is typically 18 to 22 feet long (one foot is about 0.3048 meters), a section of Range 2 (R2) drill pipe is about 27 feet to about 31 feet long and a section of Range 3 (R3) casing pipe can be between about 38 feet to about 45 feet long. Furthermore, these heavy pipes are typical round in cross-sectional shape and, therefore, these heavy pipes must be handled carefully to avoid losing control of the pipe and causing catastrophic accidents while moving the pipes between the lower surface and the elevated operational surface.

Because wells can require strings of pipe that are tens of thousands of feet long, a great deal of operational time on the rig is used to connect the individual sections of pipe. Furthermore, different types of strings of pipe are required for different operations on a given well. For example, a string of R2 drill pipe may be required to be assembled for a drilling operation. When the drilling operation is complete, the string of R2 drill pipe must then be disassembled and a string of R3 casing pipe must be assembled for a completion operation. When the completion operation is complete, then a string of R1 production pipe may be required to be assembled for producing fluids. Because each individual section of pipe is connected and disconnected by the same equipment on the elevated operational floor of the rig, this type of procedure typically occurs in series, which is very time consuming and, therefore, expensive.

SUMMARY

Some embodiments of the present disclosure relate to a pipe handling apparatus for use with an oil and gas well rig. The pipe handling apparatus for use with an oil and gas well rig, the pipe handling apparatus comprises a base that is supportable by a first surface, the base including a first end and a second end; an elongate door with a first end and a second end and that is pivotally connected to the base at the second end, the elongate door is pivotally moveable about the second end between a collapsed position and an extended position, when in the extended position the first end is positionable to abut an operational floor of a rig; a pipe carrier that is supported by the base with a first end and a second end and that is configured to receive and support a portion of at least two connected sections of pipe; a pipe carrier extension that is supported by the base, the pipe carrier extension including a first end and a second end, the second end operatively coupled to the first end of the pipe carrier, the pipe carrier extension is moveable about the second end between a collapsed position and an extended position and when in the extended position the pipe carrier extension extends beyond the base and is configured to receive and support another portion of at the least two connected pipes; and a lift member that is supported by the base, the lift member is pivotally connected at a first end to the pipe carrier and pivotally connected at a second end to the base by a collapsible extension and the lift member is moveable along the base towards and away from the second end of the elongate door.

Some embodiments of the present disclosure relate to a pipe handling system. The system comprising a connection system that is configured to connect and disconnect two individual sections of pipe; a pipe handling apparatus comprising: a base that is supportable by a first surface; an elongate door with a first end and a second end and that is pivotally connected to the base at the second end, the elongate door is pivotally moveable about the second end between a collapsed position and an extended position, when in the extended position the first end is positionable to abut an operational floor of a rig; a pipe carrier that is supported by the base with a first end and a second end and that is configured to receive and support a portion of at least two connected sections of pipe; a pipe carrier extension that is supported by the base with a first end and a second end, the second end is pivotally connected to the first end of the pipe carrier, the pipe carrier extension is moveable about the second end between a collapsed position and an extended position and when in the extended position the pipe carrier extension extends beyond the base and is configured to receive and support another portion of at the least two connected pipes; and a lift member that is supported by the base, the lift member is pivotally connected at a first end to the pipe carrier and pivotally connected at a second end to the base by a collapsible extension and the lift member is moveable along the base towards and away from the second end of the elongate door.

Without being bound by any particular theory, the aforementioned embodiments of the present disclosure may provide the benefits of a pipe handler system that reduces the amount of time that equipment upon the operational floor of an oil and gas rig are used to connect and disconnect individual sections of pipe, when making and breaking strings of pipe. The pipe handler apparatus allows for multiple sections of pipe that are already connected to be moved from a lower surface to the elevated operational floor. For example, the pipe handler apparatus can provide a pipe carrier and a pipe-carrier extension that are long enough to support two or three sections of connected pipe. When the pipe handler apparatus is used with a buck unit and pipe rack system, two or three sections of pipe can be connected and then elevated up to the operational floor, where the string assembly equipment need only make one connection. In effect, the pipe handler system of the present disclosure can provide two or more parallel operations for connecting and disconnecting sections of pipe. This means that the equipment on the operational floor can be freed up to perform other operations that it would otherwise be delayed in performing without the embodiments of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a pipe handling apparatus in a substantially collapsed position, according to embodiments of the present disclosure, wherein FIG. 1A is an isometric view of the pipe handling apparatus; and, FIG. 1B is a side-elevation view of the pipe handling apparatus.

FIG. 2 shows the pipe handling apparatus with an elongate door in an extended position, according to embodiments of the present disclosure, wherein FIG. 2A is an isometric view of the pipe handling apparatus; and, FIG. 2B is a side-elevation view of the pipe handling apparatus.

FIG. 3 shows the pipe handling apparatus with the elongate door in an extended position and a pipe carrier in a partially extended position, according to embodiments of the present disclosure, wherein FIG. 3A is an isometric view of the pipe handling apparatus; FIG. 3B is a side-elevation view of the pipe handling apparatus; and, FIG. 3C is a top-plan view of the pipe handling apparatus.

FIG. 4 shows a closer view of a portion of the pipe handling apparatus, wherein FIG. 4A shows the portion of the pipe handling apparatus within the circle “3” in FIG. 3B; and, FIG. 4B, FIG. 4C and FIG. 4D each show a linking system for moving a pipe carrier extension between a collapsed position and an extended position.

FIG. 5 shows the pipe handler apparatus with the elongate door, the pipe carrier and the pipe carrier extension in the extended position, wherein FIG. 5A is an isometric view of the pipe handling apparatus; FIG. 5B is a side-elevation view of the pipe handling apparatus; and FIG. 5C is a top-plan view of the pipe handling apparatus.

FIG. 6 shows the lift member, wherein FIG. 6A is a top plan view of the lift member in a collapsed position; FIG. 6B is a top plan view of the lift member in an extended position; FIG. 6C is two isometric views of the lift member in the collapsed position and the extended position; and, FIG. 6D is a closer view of a portion of the lift member identified in circle D, shown in FIG. 6C.

FIG. 7 shows closer views of components of the apparatus of FIG. 3, wherein FIG. 7A is an isometric view of the pipe carrier held within a channel of the elongate door; FIG. 7B shows a portion of the lifting member pivotably connected proximal the elongate door; and, FIG. 7C shows pipe carrier being supported from below by the lifting member.

FIG. 8 shows components of actuator system, wherein FIG. 8A is a top plan, partial cut away of a portion of the base that shows an actuator in a compressed position; FIG. 8B is a top plan, partial cut away of a portion of the base that shows the actuator of FIG. 8A in an extended position; and FIG. 8C is a side elevation, partial cut away view of the base.

FIG. 9 is an isometric view of an example of a rig upon a well site including a system that uses the pipe handler of FIG. 1.

FIG. 10 shows the system of FIG. 9, wherein FIG. 10A is a top-plan view of the system; and, FIG. 10B is a closer view of the circle A in FIG. 10A.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate to an adjustable object handler, which is also referred to as a pipe handler apparatus, a pipe handler assembly or a catwalk, for moving objects to and from an elevated platform. The embodiments of the present disclosure may be used in the oil drilling and rigging industries, and other appropriate industries to assist with the handling of large, heavy objects, such as a wellbore tubular, which is generally referred to herein as a length of pipe. Non-limiting examples of the applicable lengths of pipe include a joint of drilling pipe, a joint of wellbore completion tubular, a joint of well-intervention tubular, a section of wellbore casing, tubular couplers and other wellbore tubulars, as appreciated by those skilled in the art. The handling of the wellbore tubular includes, but is not limited to raising and lowering the wellbore tubular between a lower position and an elevated platform. In some embodiments of the present disclosure, the elevated platform can be part of an oil and gas rig, such as a drilling rig or a completion rig (for example: a snubbing rig or a well intervention rig or as otherwise understood by those skilled in the art). The embodiments of the present disclosure relate to a mobile pipe-handling apparatus that is capable of transferring at least two lengths of connected pipe (which may also be referred to as a length of two connected pipes or two connected lengths of pipe and the like) from a generally horizontal storage-position below the elevated platform to a near vertical-position above the elevated platform. Some embodiments of the present disclosure relate to a modular pipe handling apparatus that can be modified, with minor adjustments, to facilitate use with elevated platforms of different heights. In some embodiments of the present disclosure, the apparatus may be automatically controlled, such that operating personnel may control the system remotely through electronically controlled systems, such as electronic motors, pneumatic systems, hydraulic systems or combinations thereof.

FIG. 1 depicts one embodiment of a pipe handling apparatus 100 according to embodiments of the present disclosure. As will be appreciated by those skilled in the art, the pipe handling apparatus 100 can be positioned adjacent an oil and gas rig, such as a drilling rig or a completions rig (not shown). The pipe handling apparatus 100 can be made of various materials provided the materials comprise the necessary strength properties to support and move two or more sections of connected pipe that can weight upwards of 15,000 pounds. In general, the components of the pipe apparatus 100 are made of metal, metal alloys or combinations thereof. In order to reduce the weight of the components of the pipe handling apparatus 100, various weight saving features may be incorporated, such as weight-saving apertures throughout each component (as shown in the figures). The person skilled in the art will appreciate that components of the pipe handling apparatus 100 are generally symmetrical about a longitudinal midline. As such, the discussion below will generally describe one side of each component with the understanding that such a description is equally applicable to the opposite side of the component being described, unless otherwise indicated herein below.

As shown at least in FIG. 1A and FIG. 1B, the apparatus 100 comprises the components of a base 10, an elongate door 20, a pipe carrier 30, a pivotable pipe carrier extension 31 and a lift assembly 40 (shown in FIG. 5A). The pipe handling apparatus 100 can move between a collapsed position (FIG. 1), one or more intermediate positions (as shown at least in FIG. 2 and FIG. 3) and an extended position (as shown at least in FIG. 5). As utilized herein, the term “stroke” refers to a partial or complete movement of one or more components of the pipe handling apparatus 100 with respect to another component. For example, as the apparatus 100 moves from the collapsed position, the elongate door 20 pivotally moves through at least a portion of a stroke to one or more intermediate positions (compare FIG. 1 with FIG. 2). The apparatus 100 can move through a further portion of the stroke (or a complete stroke) as the pipe carrier 30 moves from the intermediate position to the extended position (compare FIG. 2 and FIG. 3 and FIG. 5). As the components of the pipe handling apparatus 100 move through these various positions, a length of at least two connected pipes (not shown) can be moved from a substantially horizontal position upon the pipe carrier 30, while the apparatus 100 is in the intermediate position shown in FIG. 2, proximal to the base 10 to the fully extended position (as shown at least in FIG. 5). When the length of at least two connected pipes are moved from the substantially horizontal position proximal to the base 10, as the pipe handling apparatus 100 moves through to the extended position, the length of at least two connected pipes is moved upwardly to become proximal to an upper operational floor of a rig. From this position, the length of at least two connected pipes is moved by further components of the rig (not shown) to occupy a substantially vertical position for connection to a waiting section of pipe and for insertion into the wellbore below the rig. As will be appreciated by those skilled in the art, the movement and functions of the pipe handling apparatus 100 can also be operated in reverse so as to lower the length of at least two connected pipes from the elevated position upon the pipe carrier 30 (when the pipe handling apparatus 100 is in the extended position) to a substantially horizontal position proximal to the base 10 (when the pipe handling apparatus 100 is in the intermediate position). While the discussion below describes the movement of the pipe handling apparatus 100 from the collapsed position to the extended position, for moving the length of two or more connected pipes from the substantially horizontal position to proximal to the operational floor of the rig, the person skilled in the art will appreciate that the reverse movements of the pipe handling apparatus 100 are similarly contemplated herein.

The base 10 can be supported directly on a surface (not shown) such as the ground or a lower floor of a rig. The base 10 defines a first end 10A and a second end 10B, which together define a longitudinal axis of the base 10. In some embodiments of the present disclosure the base 10 may be elongate along the longitudinal axis; however, this is not necessary. The base 10 is configured to support the elongate door 20, the pipe carrier 30, the pipe carrier extension 31 and the lift assembly 40 while these components support and move a length of two or more connected pipes between a lower surface and an upper surface.

As shown at least in FIG. 1A and FIG. 1B, the base 10 can be operatively coupled to and support the elongate door 20 at least by a coupler 22, for example a triangle linker. The elongate door 20, which can also be referred to as a V door, has a first end 20A and a second end 20B, together which define a longitudinal axis of the elongate door 20.

Also shown in FIG. 2, the base 10 comprises multiple pipe rack arms 12. The non-limiting example shown in FIG. 2 depicts five pipe rack arms 12A, 12B, 12C, 12D and 12E; however, more or less pipe rack arms 12 may be utilized depending on the actual length of the two or more connected pipes that the apparatus 100 is moving. As discussed further below, the pipe rack arms 12 are configured to cooperate with a pipe indexer system to receive a length of two or more connected pipes, typically from a side of the base 10 and to direct the length of two or more connected pipes to rest upon the pipe carrier 30.

FIG. 2A shows the apparatus 100 in the intermediate position with the elongate door 20 in an extended position, which it occupies by a pivoting movement about a pivot assembly 21 (see FIG. 2B) that is positioned between the second end 10B of the base 10 and the second end 20B of the elongate door 20. FIG. 2B also shows the elongate door 20 in the extended position where the first end 20A is positionable to abut a portion of the upper operational floor of the rig (not shown). In some embodiments of the present disclosure, the elongate door 20 may be constructed of two bodies 20C and 20D that are connected to each other by cross members (not shown) and that define a guide channel 20E therebetween. The guide channel 20E may further comprise a floor that is defined by cross-members that extend between interior, lateral walls of the bodies 20C and 20D. The guide channel 20E is configured to receive a portion of the pipe carrier 30 therein and to restrict lateral movement of the pipe carrier 30 as a portion of the pipe carrier 30 moves along (upwardly or downwardly) the elongated door 20. In other embodiments of the present disclosure, the guide channel 20E may be defined by a single body or more than two bodies.

The pipe carrier 30 comprises a first end 30A and a second end 30B, which together define a longitudinal axis of the pipe carrier 30 (see FIG. 3A). The pipe carrier 30 may also comprise a skate assembly 34 that is positioned proximal to the first end 30A of the pipe carrier 30. As will be appreciated by the person skilled in the art, the skate assembly 30 can slidably move along the longitudinal axis of the pipe carrier 30. The skate assembly 30 is configured to receive and releasably secure an end of the length of two or more connected pipes. As such, in some embodiments of the present disclosure, the skate assembly 34 can slidably move along a longitudinal axis of the extension 31 as well. The skate assembly 30 may restrict longitudinal movement of the length of two or more connected pipes as it is moved upon the pipe carrier 30 from proximal to the base 10 to proximal to the first end 20A of the elongate door 20 in the extended position.

In some embodiments of the present disclosure, the pipe carrier 30 can include at least one pair of safety bars 41. The safety bars 41 may be rotatably coupled to each side of the pipe carrier 30 and when rotated into the extended position the safety bars 41 are configured to restrict or reduce lateral movement of the length of at least two connected pipes when being moved upon the pipe carrier 30 between the lower surface and the upper operational surface. For example, the safety bars 41 may help maintain a position of the length of pipe within the pipe carrying groove 37. FIG. 4A shows one example of a safety bar 41 in a retracted position and in an extended position (shown as dotted line feature 41A).

FIG. 1 also shows the pipe carrier extension 31 in a collapsed position. The pipe carrier extension 31 comprises a first end 31A and a second end 31B. In the collapsed position, the pipe carrier extension 31 may be positioned above the base 10 (see FIG. 1A). In particular, the first end 31A can be positioned above the base 10 and above the pipe carrier 30. The second end 31B is pivotably connected to the base 10, proximal the second end 10B so that the extension 31 can pivot about the second end 31B to move into an extended position (see FIG. 2). When in the extended position, the extension 31 can be functionally aligned with the longitudinal axis of the pipe carrier 30 with the second end 31B coupled to the first end 30A of the pipe carrier 30. The pipe carrier extension 31 comprises many of the same components as the pipe carrier 30 so that the pipe carrier 30 and the extension 31 together can support a length of two or more connected pipes as they are received and moved from a lower level to an upper level.

For clarity, the length of two or more connected pipes refers to two or more connected pipes that are used in an oil and/or gas well. These pipes are heavy and can weight upwards of about 15,000 pounds (one pound is equivalent to about 0.45 kilograms). In addition to their weight, these heavy pipes are also long. For example, typical examples of pipes used in oil and/or gas wells include: Range 1 (R1) pipe of which one section is about 18 to about 24 feet long (one foot is about 0.305 meters), Range 2 (R2) drill pipe of which one section is about 27 feet to about 31 feet long, and Range 3 (R3) casing pipe of which one section can be between about 38 feet to about 45 feet long. Furthermore, these heavy pipes are typical round in cross-sectional shape and, therefore, these heavy pipes must be handled carefully to avoid losing control of the pipe and causing catastrophic accidents while moving the pipes between the lower surface and the elevated operational surface. The embodiments of the present disclosure provide the apparatus 100 that is configured to receive and move a length of at least two sections of connected pipe between a lower level to an upper level. Some embodiments of the present disclosure relate to the apparatus 100 that is configured to receive and move a length of at least two connected pipes that is between about 30 feet and about 150 feet long. For example, when R1 pipe is being used, the apparatus 100 can receive and move a length of two connected R1 pipes that is between about 36 feet to about 48 feet long. The apparatus 100 can also receive and move a length of three connected R1 pipes that is between about 54 feet to about 72 feet long. When R2 pipe is being used, then the apparatus 100 can receive and move a length of two connected R2 pipes that is between about 54 feet to about 62 feet long. The apparatus 100 can also receive and move a length of three connected R2 pipes that is between about 81 feet to about 93 feet long. When R3 pipe is being used, then the apparatus 100 can receive and move a length of two connected R3 pipes that is between about 76 feet to about 90 feet. The apparatus 100 can also receive and move a length of three connected R3 pipes that is between about 114 feet and about 135 feet long.

FIG. 3A and FIG. 3B show different views of the pipe assembly 100 with the elongate door 20 in the extended position and the pipe carrier 30 and the lift member 40 in an intermediate position. As will be described herein further below, an actuator system 80 may be used to move the pipe carrier 30 towards and away from the first end 20A of the elongate door 20. As this occurs, the lift member 40 supports the pipe carrier 30 from below so that the second end 30B of the pipe carrier 30 can slidingly move up and down the elongate door 20, for example being laterally constrained by the side walls of the guide channel 20E, as discussed further below.

The second end 30B of the pipe carrier 30 comprises a first bearing surface 38A that is positioned to bear against at least the floor of the guide channel 20E when the pipe carrier 30 is moving along the elongate door 20. In some embodiments of the present disclosure the first bearing surface 38A may include one or more rotatable members, such as wheels or rollers, to facilitate movement of the pipe carrier 30 along the guide channel 20E.

FIG. 4 shows a closer view of a portion of the apparatus 100 where the second end 31B of the extension 31 is operatively coupled to the pipe carrier 30. In some embodiments of the present disclosure, this portion of the apparatus 100 comprises a lift system 33 that is configured to lift the first end 31A of the carrier extension 31. The lift system 33 comprises at least one rolling member 33A and one ramp member 33B (see FIG. 4A). The rolling member 33 is connected to the lower surface of the pipe carrier 30 or the pipe carrier extension 31 or both. The rolling member 33 is configured to rotate and assist in moving the pipe carrier 30 and the pipe carrier extension along the ramp member 33B. The ramp member 33B may be positioned within a housing space 11 that is defined by the base 10 (see FIG. 8C). The ramp member 33B may have a first portion that is substantially parallel to the longitudinal axis of the base 10 and a second portion that diverts from being parallel to the longitudinal axis of the base 10 at an angle α. In some embodiments of the present disclosure, the angle a is substantially constant along the length of the second portion; however, in other embodiments, the second portion may include different angles. The first portion of the ramp member 33B may have one end defined by a shoulder 11A that is positioned at the first end 10A of the base 10. The first portion of the ramp member 33B extends until the second portion. The second portion diverts at the angle a and may extend to proximal to an upper surface of the base 10. So that, when the carrier extension 31 is moved to the extended position and when the pipe carrier 30 and the pipe carrier extension 31 are moved towards the elongate door 20, both horizontally and vertically, the rolling member 33A will move along the first portion of the ramp member 33B and then begin to advance upwardly along the second portion of the ramp member 33B. As the rolling member 33A advances upwardly, it will cause the pipe carrier 30 and the carrier extension 31 to also lift vertically. This vertical lift will allow the first end 31A of the carrier extension 31 to also lift vertically so as to avoid engaging and digging into the surface that is supporting the base 10. When the pipe carrier 30 and carrier extension 31 are returned to the collapsed position, the rolling member 33A will move along the ramp member 33B and come to abut the shoulder 11A. As will be appreciated by those skilled in art, the distance that the first end 31A of the carrier extension 31 extends away from the first end 10A of the base 10, when the carrier extension 31 is in the extended position, will dictate the amount of lift required to avoid contacting the surface that supports the base 10. As such, the angle a and the length of the second portion of the ramp member 33B can be designed to achieve this goal while considering the mechanical advantage gained by using the ramp member 33B to achieve the vertical lift. As will be appreciated by those skilled in the art, the lift system 33 may comprise multiple rolling members 33A and multiple ramp members 33B that are positioned within the housing space 11 or outside of the housing space 11 that collectively may contribute towards providing the vertical lift of the first end 31A.

FIG. 4B, FIG. 4C and FIG. 4D show the carrier extension 31 as it moves relative to the pipe carrier 30, through three positions: the collapsed position (FIG. 4B), an intermediate position (FIG. 4C) and the extended position (FIG. 4D). In some embodiments of the present disclosure, the movement of the carrier extension 31 may be a pivoting movement that is generally about the first end 30A of the pipe carrier 30 that is caused by a linkage system 35. The linkage system 35 may be used in various applications (other than moving the carrier extension 31 between the collapsed and extended positions) that require moving a first member from a first position that is substantially parallel to a second member to a second position that is also substantially parallel but also coaxial with the second member where such movement is about a pivot point. In the non-limiting example of FIG. 4B, FIG. 4C and FIG. 4D, the linkage system 35 comprises a first actuator 35A, a second actuator 35B and a link member 35C. The actuators 35A and 35B may be hydraulically powered, pneumatically powered, electronically powered or a combination thereof. Each actuator 35A and 35B may be a reciprocating actuator that can move between a retracted position and an extended position. In some embodiments of the present disclosure, the actuators 35A and 35B are hydraulic cylinders that are powered by a power system of the apparatus 100, described further below. The linking member 35C is configured to facilitate the pivoting movement of the carrier extension 31 about the first end 30A. For example, one end of the actuator 35A may be rotatably coupled to a sidewall of the pipe carrier extension 31 with the other end rotatably coupled to linking member 35C. Similarly, the actuator 35B may be rotatably coupled to a sidewall of the pipe carrier 30 at one end with the other end rotatably coupled to the linking member 35C, generally opposite to where the actuator 35A is coupled. The pipe the linking member 35C may be pivotably coupled to each of the side wall of the pipe carrier 30 and the pipe carrier extension by one or more pivot members. The pivot members may be pivot pins or shanks that extend from the side wall of the pipe carrier (or the pipe carrier extension as the case may be) and that are received in pivot apertures defined by the linking member 35C, or vice versa. In operation, in some embodiments of the present disclosure when the pipe carrier extension 31 is in the collapsed position, both of the actuators 35A, 35B may be extended (see FIG. 4B). To move the pipe carrier extension 31 into the intermediate position, the actuator 35B may retract causing the linking member 35C to rotate and the pipe carrier extension 31 to pivot about the first end 30A of the pipe carrier 30 (see FIG. 4C). To move the pipe carrier extension 31 in to the extended position, the actuator 35A can then retract, pulling the pipe carrier extension 31 into the extended position (see FIG. 4D).

In other embodiments of the present disclosure, the carrier extension 31 may be operatively coupled to the pipe carrier 30 by another mechanism. For example, the carrier extension 31 may be configured to be received within the housing space 11 of the base 10 or about a portion of the base 10 in a nested configuration. In other examples, the carrier extension 31 may be operatively connected to the pipe carrier 30 by a pivot hinge so that the carrier extension 31 can be pivoted about the pivot hinge and move into a collapsed positioned adjacent a sidewall of the pipe carrier 30 or the base 10.

Also as shown in FIG. 5, the pipe carrier 30 may further comprise an upper carrier extension 36 that extends from the second end 30B of the pipe carrier 30. In some embodiments of the present disclosure the upper carrier extension 36 may be pivotally connected to the second end 30B, for example at a pivot point 31. In some embodiments of the present disclosure, the upper carrier extension 36 may comprise a second bearing surface 38B that are positioned to bear against at least the floor of the guide channel 20E when the pipe carrier 30 is moving along the elongate door 20. In some embodiments of the present disclosure, the second bearing surface 38B may include one or more rotatable members, such as wheels or rollers, to facilitate movement of the upper carrier extension 36 along the guide channel 20E. FIG. 7A shows the second end of the pipe carrier 30 with the upper carrier extension 36 acting as the second bearing surface 38B when the pipe carrier 30 is captured within the guide channel 20E proximal the first end 20A of the elongate door 20.

In some embodiments of the present disclosure, the pipe carrier 30 can held at and not past the first end 10A of the elongate door 20 with the upper carrier extension 36 no longer bearing against the elongate door 20 with the first bearing surface 38A abutting a portion of the first end 20A of the elongate door 20 (see FIG. 5). The first end 20A of the elongate door 20 may define a first shoulder that can cooperate with a second shoulder that is defined by the pipe carrier 30 to act as a stop and to maintain capture of the pipe carrier 30 within the guide channel 20E.

In some embodiments of the present disclosure, the first end 10A of the base 10 is configured to house a power system. The power section is configured to receive input commands from an operator and to translate those commands into sending move commands to various components of the pipe handler apparatus 100. The user commands may be in the form of electronic signals that are translated into move commands by a controller unit. In some embodiments of the present disclosure the controller unit can translate the electronic command signals from the user into hydraulic commands that are communicated through one or more hydraulic circuits of the pipe handler apparatus 100. For example the power system may further comprise a motor that is operatively connected to a hydraulic drive unit. The hydraulic drive unit is in fluid communication with a reservoir of hydraulic fluid so that the hydraulic drive unit can control the flow of the hydraulic fluid to and from the reservoir by controlling the position of one or more hydraulic valves. As will be appreciated by those skilled in the art, the power system can operate in a similar fashion as known programmable logic controller controlled hydraulic drive systems. Examples of some components that can be moved by the power system include: pivoting the elongate door 20 between the collapsed and extended positions, pivoting the extension 31 between the collapsed and extended positions the pipe rack arms 12, the pipe carrier 30 and extension 31 for movement along the elongate door 20, the components of the pipe kicker system and the actuator system 80 (as described further herein below).

The pivoting movement of the elongate member 20 relative to the second end 10B of the base 10 is due to the action of the pivot assembly 21 that comprises a pivot point, one or more first actuators, such as one or more hydraulic cylinders, that bear against a portion of the second end 20B of the elongate door 20 and the coupler 22 and one or more second actuators, such as one or more hydraulic cylinders, that bear against a portion of the second end 10B of the base 10 and the coupler 22. Either of the first actuator or the second actuator can extend to provide a first portion of a stroke to move the elongate door 20 from the collapsed position. The other actuator (i.e. either the second actuator 26B or the first actuator 26A, as the case may be) may then extend to provide the second portion of the stroke to move the elongate door from an intermediate position to the fully extended position. During the first portion and second portion of this stroke the second end 20B of the elongate door 20 pivots relative to the second end 10B of the base, about the pivot point 28. The pivot point 28 can comprise a pivot connector, such as a pin, that fits within components defined of both the base 10 and the elongate door 20 for pivotably coupling (which may also be referred to as pivotally connecting) the base 10 and the elongate door 20.

Either or both sides of the pipe carrier 30 may comprise one or more safety bars and the pipe carrier 30 may define a pipe carrying groove 37 that extends along the longitudinal axis of the pipe carrier 30. In some embodiments of the present disclosure, the extension 31 also includes one or more safety bars on either or both sides. The pipe carrying groove 37, the safety bars and the skate assembly 34 cooperate to restrict movement of the length of pipe that is being carried upon the pipe carrier 30 and the extension 31. The apparatus 100 may further comprise a safety bar link that operatively links the rotation of the safety bars on the same side of the pipe carrying groove 37 to allow the entry or exit of the length of pipe onto or from the pipe carrier 30, and optionally the extension 31, on either side.

As shown FIG. 5 and FIG. 6, the lift member 40 comprises a first end 40A and a second end 40B, which together define a longitudinal axis of the lift member 40. The lift member 40 is slidably and rotatably moveable within the base 10. The first end 40A of the lift member 40 is pivotally connected proximal to the first end 30A of the pipe carrier 30. The second end 40B of the lift member 40 is pivotally connected to the base 10, proximal to the second end 10B by one or more pivotable connections 44. In some embodiments of the present disclosure, the lift member 40 comprises a lift extension 43 that extends past the second end 40B of the lift arm 40 to pivotally connect with a portion of the base 10, or to pivotally connect with a portion of the second end 20B of the elongate door 20, or both. The lift extension 43 may be reversibly collapsible to allow for the lift member 40 to advance and retract away from the second end of the base 10B while the second end 40B of the lift member 40 is held in position by one or more pivotable connections of the extension 43. In operation, as the pipe carrier 30 moves upwardly along the elongate door 20, the lift member 40 slidably moves towards the second end 10B of the base 10 and this causes the lift extension 43 to collapse, thus shortening the overall length of the lift member 40. When the lift member 40 has travelled as far as it can along the base 10 towards the second end 10B, for example because there is no further play to collapse, then the second end of the lift assembly 40B forms a pivot point with the second end 10B or the second end 20B or both, as the case may be. As shown in FIG. 6DE, the lift extension 43 may define the one or more pivotable connections 44 and a shoulder 45. The shoulder 45 is configured to prevent further collapsing of the lift member 40 such that when the second end 40B abuts the shoulder 45 the continued upward movement of the pipe carrier 30 along the elongate door 20 causes the lift member 40 being to pivot about the one or more pivotable connections 44 that are proximal the second end 40B. In some embodiments of the present disclosure, the lift member 40 and the lift extension 43 are arranged in a nested configuration so that when the lift member 40 slides towards the second end 20B of the elongate door 20, at least a portion of the lift extension 43 is received within the second end 40B, or vice versa. In other words, the lift extension 43 and the second end 40B may be in a telescopic arrangement to allow the lift member 40 to be reversibly collapsible. However, as will be appreciated by those skilled in the art, other mechanisms or materials can be employed to provide the reversible collapsibility of the lift member 40.

Because the first end of the lift member 40A is pivotally connected to the first end 30A of the pipe carrier 40, the first end of the lift member 40A is lifted upwardly, in a pivoting and arcuate fashion to a position that supports the pipe carrier 30 when it is held in the extended position. This is another manner by which embodiments of the present may provide full capture of the pipe carrier 30 as it moves up and down the elongate door 20. Furthermore, when the pipe carrier 30 is held at and not past the first end 20A, the longitudinal axis of the lift member 40 can be at an angle a that is less than 90 degrees (i.e. less than vertical), which may also contribute towards the capture of the of pipe carrier 30 within the carrier groove 20E.

FIG. 7A shows a closer view of the second end 40B of the lift member 40 when the second end 30B of the pipe carrier 30 is captured within the carrier groove 20E of the elongate door 20. In this position, the upper carrier extension 36 can extend towards the operational floor of the rig to facilitate the movement of the length of pipe from the pipe carrier to and from the operational floor. In some embodiments of the present disclosure, the first bearing surface 38A of the pipe carrier 30 is held at and not past the first end 20A of the elongate door 20. This is one manner by which the pipe carrier 30 is captured during all movements between the collapsed position and the extended position, and vice versa.

FIG. 7B shows a closer view of the second end 40B of the lift member 40 when the second end 30B of the pipe carrier 30 is captured within the carrier groove 20E of the elongate door 20. FIG. 7C shows a closer view of the first end 30A of the pipe carrier 30 when the lift member 40 has moved pivotally and arcuately to support beneath the pipe carrier 30.

FIG. 7C also shows the first end of the pipe carrier 30A as comprising a third bearing surface 37. The third bearing surface 37 bears against a portion of the base 10 as the pipe carrier 30A initiates its movement along the carrier groove 20E or as it completes its movement into the collapsed position. In some embodiments of the present disclosure the third bearing surface 37 comprises one or more rotatable members 39, such as one or more wheels or rollers.

FIG. 8A, FIG. 8B and FIG. 8C depict aspects of the actuator system 80 that comprises at least an actuator, a shiv and a cable, where the system is employed to move the pipe carrier 30 along the elongate door 20. FIG. 8A shows at least one actuator 62 that is reversibly extendible within the housing 11 of the base 10 (shown in FIG. 8C). The actuator 62 can move substantially along the longitudinal axis of the base 10. Fixed at an end of the actuator 62 that is closest to the first end 10A, is a first shiv 64 (note that FIG. 8A and FIG. 8B are partial cut away views and that is why only one shiv is depicted). In some embodiments of the present disclosure, the actuator 62 is a hydraulic cylinder that is part of the power system hydraulic circuit. Whereby the flow of hydraulic fluid into the cylinder causes the actuator 62 to extend and move the first shiv 64 towards the first end 10A of the base 10. FIG. 8A shows the actuator 62 in a non-extended position (compressed position) and FIG. 8B shows the same view with the actuator 62 extended, hence the first shiv 64 is no longer in view.

FIG. 8C shows a set of second shivs 66 that are positioned proximal the second end 10B of the base 10. A third shiv 68 that is positioned proximal the first end of the elongate door 20 (see FIG. 2B). A cable (not shown) is fixed at one end at a cable fixing point 73 on the base 10 and at an opposite end at cable fixing point on the pipe carrier 30. Between the two fixing points 72, the cable 70 extends at least partially about the first shiv 64 (at one end of the actuator 62), at least partially about the second shiv 66 (proximal the second end 10B) and at least partially about the second shiv 68. So that when the actuator 62 extends, the cable 70 pulls the pipe carrier 30 to move-in this case upwardly along the elongate door 20. If the actuator 62 is moved towards the non-extended position, the cable 70 will allow the pipe carrier 30 (under the force of gravity, its own weight) to move-in this case downwardly-along the elongate door 20. As will be appreciated by the person skilled in the art, the first shiv 64, the second shiv 66 and the third shiv 68 can each be two or more shivs positioned as described above.

In some embodiments of the present disclosure, the elongate door 20 may include one or more connector plates that are configured to releasably receive one or more connectors therethrough, for example bolts. The connector plates are configured to secure different longitudinal sections of the elongate door 20 together. The connector plates allow the length of the elongate door 20 to be adjusted so that the pipe handler apparatus 100 is modular and can be used with rigs that have different operational floor heights.

As shown in FIG. 9 and FIG. 10, the apparatus 100 can be used with a system 200 that can be used with a rig 300 for assembling and disassembling a string of pipe that can extend into a well (not shown) that is positioned below the rig 300. The system 200 is configured to receive a first pipe 500A and a second pipe 500B from a pipe rack system 202 that is configured to retain multiple individual joints of pipe 500. The term joint of pipe may also be referred to herein as a length of pipe or a section of pipe. The system 200 is further configured to threadably connect the first and second pipes 500A, 500B via a connection system 204 to form a length of at least two connected pipes 500C. As will be appreciated by those skilled in the art, the pipe rack system 202 can provide multiple first and second pipes 500A, 500B in order for the system 200 to form multiple lengths of at least two connected pipes 500C.

The pipe rack system 202 may include a first rack 202A that is configured to receive and retain the multiple individual joints of pipe 500 and to advance an individual joint of pipe 500 from the first rack 202A into a transition rack system 202B. For example, the first rack 202A may be slanted so that the end of the first rack 202A that is closest to the transition rack system 202B is lower than the opposite end of the first rack 202A. The lower end may comprise an indexing system, such as one or more indexing gates, for controlling the rolling movement of a pipe from the first rack 202A on to the transition rack system 202B in a controlled fashion. The transition rack system 202B may be adjustable, in terms of height, and horizontal position, so that when it receives a pipe from the first rack 202A it can adjust the position of the received pipe for delivery to the connection system 204.

In some embodiments of the present disclosure, the connection system 204 may comprise a bucking machine 204A that is configured to receive a pipe from the transition rack system 202B along the pipe's longitudinal axis so that one end of the first pipe 500A is positioned within the bucking machine 204A. Next the system 200 can deliver the second pipe 500B with an end thereof positioned in the bucking machine 204A so that the bucking machine 204A can threadable connected the first pipe 500A and the second pipe 500B to form a length of at least two connected pipes 500C. Once connected, the length of at least two connected pipes 500 can be rolled (about its longitudinal axis) laterally out of the bucking machine 204A to a pipe kicker system 206. The pipe kicker system 206 is positioned between the bucking machine 204A and the apparatus 100. The pipe kicker system 206 is configured to control rolling movement of the length of at least two connected pipes 500C between the connection system 204 and the apparatus 100 so that the length 500C can be placed upon the pipe carrier 30 for movement from the lower surface up to an upper operational surface of the rig 300. The pipe kicker apparatus 206 may comprise one or more pipe index stop pins, one or more pipe indexers and one or more pipe kickers.

In some embodiments of the present disclosure, the system 200 is configured to connect three individual joints of pipe together to make a length of three connected pipes that are then received upon the apparatus 100 for movement between the lower level 300A and the upper operational level 300B of the rig 300.

FIG. 9 shows the elongate door 20 as being in the extended position and abutting the elevated operational floor 300B of the rig 300. As will be appreciated by those skilled in the art, the system 200 may also be configured to connect a third pipe to the length of already connected first and second pipes 500A, 500B so that the length of at least two connected pipes 500C includes three lengths of already connected pipe.

As will also be appreciated by those skilled in the art, the system 200 is also configured to receive a length of at least two connected pipes from the rig 300. For example, the rig 300 can position the length of at least two connected pipes upon the pipe carrier 30 and the apparatus 100 can be operated as described hereinabove to lower the received length of at least two connected pipes down to same level as the connection 204 so that the length of at least two connected pipes can be disconnected and broken down into individual lengths of pipe by reversing the action of the bucking machine 204A. The system 200 is further configured to move the individual lengths of pipe to the pipe tub 202 for storage until further use.

As will be appreciated by those skilled in the art, the system 200 provides the ability to connect and disconnect individual sections of pipe, via the connection system 204. The implications of which are that the components of the rig 300 are not required to be dedicated to making and breaking every single threaded connection that is required to assemble and disassemble the entire pipe string. Instead, the rig 300 can be used solely for connecting or disconnecting every other (second) or every third connection. For example, the rig 300 is only required to connect each length of at least two connected pipes to assemble the pipe string and the rig 300 is only required to disconnect each length of at least two connected pipes to disassemble the pipe string. Because the apparatus 100 is configured to move the length of at least two connected pipes between the lower level and the upper operational floor of the rig 300, the connection system 204 can be employed to make and break the lengths of at least two connected pipes 500C.

Some embodiments of the present disclosure relate to a pipe handling apparatus for use with an oil and gas well rig. The pipe handling apparatus comprising a base, an elongate door, a pipe carrier and a lift member. The base that is supportable by a first surface. The elongate door comprises a first end and a second end and is pivotally connected to the base at the second end. The elongate door is pivotally moveable about the second end between a collapsed position and an extended position. When the elongate door is in the extended position the first end is positionable to abut an operational floor of a rig. The pipe carrier comprises a first end and a second end that is supported by the base and that is configured to receive and support an elongate pipe. The lift member is supported by the base and is pivotally connected at a first end to the pipe carrier and pivotally connected at a second end to the base by a collapsible extension. The lift member is moveable along the base towards and away from the second end of the elongate door. When the lift member moves towards the second end of the elongate door, the collapsible extension collapses forming a pivot point and causing the first end of the lift member to moves upwardly and arcuately towards the elongate door.

Further embodiments of the present disclosure relate to a pipe handling apparatus for use with an oil and gas well rig. The pipe handling apparatus comprises a base, an elongate door, a pipe carrier and a lift member. The base is supportable by a first surface. The elongate door comprises a first end and a second end and is pivotally connected to the base at the second end. The elongate door is pivotally moveable about the second end between a collapsed position and an extended position. When the elongate door is in the extended position the first end is positionable to abut an operational floor of a rig. The pipe carrier is supported by the base and comprises a first end and a second end that is supported by the elongated door and that is configured to receive and support an elongate pipe. The second end comprising a bearing surface that is moveable along the elongate door. The lift member is supported by the base and the lift member is pivotally connected at a first end to the pipe carrier and pivotally connected at a second end to the base. The lift member is also moveable along the base towards and away from the second end of the elongate door. When the lift member moves towards the second end of the elongate door, the lift member moves upwardly and arcuately for elevating the second end of the pipe carrier towards and not past the first end of the elongate door.

Further embodiments of the present disclosure relate to a pipe handling apparatus for use with an oil and gas well rig. The pipe handling apparatus comprising a base, a power section, an elongate door, a pipe carrier and a cable. The base is supportable by a first surface. The base comprises a first end and a second end and is configured to house an actuator that comprises a first shiv connected thereto. The actuator is configured to move between a contracted position and an extended position. The power section is configured to move the actuator between the contracted position and the extended position. The elongate door comprises a first end and a second end and is pivotally connected to the base at the second end. The elongate door is pivotally moveable about the second end between a collapsed position and an extended position. When the elongate door is in the extended position, the first end is positionable to abut an operational floor of a rig. The elongate door further comprises a second shiv positioned proximal the second end and a third shiv positioned proximal the first end. The pipe carrier comprises a first end and a second end and is configured to receive and support an elongate pipe. The cable is connected at a first end to the base and is connected at a second end to the carrier arm. The cable also extends about a portion of the first shiv, about a portion of the second shiv and about a portion of the third shiv. When the actuator moves towards the extended position, under control of the power section, the cable travels about at least a portion of the first shiv, at least a portion of the second shiv and at least a portion of the third shiv to cause the second end of the pipe carrier to move upwardly towards the first end of the elongate door.

Further embodiments of the present disclosure relate to a pipe handling apparatus for use with an oil and gas well rig. The pipe handling apparatus comprises a base, an elongate door, a coupler, a first actuator, a second actuator and a power section. The base is supportable by a first surface. The elongate door comprises a first end and a second end and that is pivotally connected to the base at the second end. The elongate door is pivotally moveable about the second end between a collapsed position and an extended position. When the elongate door is in the extended position, the first end is positionable to abut an operational floor of a rig. The coupler is positioned between the base and the second end. The first actuator is operatively coupled to a first end of the coupler and the elongate door. The second actuator is operatively coupled to a second end of the coupler and the base. The power section is configured to move the first actuator and the second actuator each between a contracted position and an extended position. Movement of the first actuator moves the elongate door through a first portion of between the collapsed position and the extended position and wherein movement of the second actuator moves the elongate door through a second portion of the between the collapsed position and the extended position.

Claims

1. A pipe handling apparatus for use with an oil and gas well rig, the pipe handling apparatus comprising:

(a) a base that is supportable by a first surface, the base including a first end and a second end;

(b) an elongate door with a first end and a second end and that is pivotally connected to the base at the second end, the elongate door is pivotally moveable about the second end between a collapsed position and an extended position, when in the extended position the first end is positionable to abut an operational floor of a rig;

(c) a pipe carrier that is supported by the base with a first end and a second end and that is configured to receive and support a portion of at least two connected sections of pipe;

(d) a pipe carrier extension including a first end and a second end, the second end operatively coupled to the first end of the pipe carrier, the pipe carrier extension is moveable about the second end between a collapsed position and an extended position and when in the extended position the pipe carrier extension extends beyond the base and is configured to receive and support another portion of at the least two connected pipes; and

(e) a lift member that is supported by the base, the lift member is pivotally connected at a first end to the pipe carrier and pivotally connected at a second end to the base by a collapsible extension and the lift member is moveable along the base towards and away from the second end of the elongate door.

2. The apparatus of claim 1, further comprising a linking system that is configured to operatively couple the pipe carrier extension to the first end of the pipe carrier.

3. The apparatus of claim 2, wherein the linking system comprises an actuator and a linking member, wherein the actuator is configured to pivot the pipe carrier extension about one or more pivot points of the linking member.

4. A system for handling a length of at least two connected pipes, wherein the system comprises:

(a) a connection system that is configured to connect and disconnect two individual sections of pipe;

(b) a pipe handling apparatus comprising: (i) a base that is supportable by a first surface; (ii) an elongate door with a first end and a second end and that is pivotally connected to the base at the second end, the elongate door is pivotally moveable about the second end between a collapsed position and an extended position, when in the extended position the first end is positionable to abut an operational floor of a rig; (iii) a pipe carrier that is supported by the base with a first end and a second end and that is configured to receive and support a portion of at least two connected sections of pipe; (iv) a pipe carrier extension that is supported by the base with a first end and a second end, the second end is pivotally connected to the first end of the pipe carrier, the pipe carrier extension is pivotally moveable about the second end between a collapsed position and an extended position and when in the extended position the pipe carrier extension is configured to receive and support another portion of at the least two connected pipes; and (v) a lift member that is supported by the base, the lift member is pivotally connected at a first end to the pipe carrier and pivotally connected at a second end to the base by a collapsible extension and the lift member is moveable along the base towards and away from the second end of the elongate door.

5. The system of claim 4, further comprising a pipe kicker system that is configured to move the length of at least two connected pipes between the connection system and the pipe handling apparatus.

6. The system of claim 4, further comprising a pipe tub system that is configured to deliver and receive individual sections of pipe to and from the connection system.

7. The system of claim 4, wherein the connection system comprises a bucking machine.

8. The system of claim 7, wherein the bucking machine is configured to connect a first pipe and second pipe to form a length of at least two connected pipes and, wherein the bucking machine is further configured to release the length of at least two connected pipes in a direction that is substantially perpendicular to a longitudinal axis of the length.