ADJUSTABLE TUBULAR ELEVATOR

Description

CLAIM OF PRIORITY

This patent application claims the benefit of priority as a continuation-in-part of Krijnen et al., U.S. patent application Ser. No. 18/626,981, entitled “ADJUSTABLE rig floor slip,” filed on Apr. 4, 2024 (Attorney Docket No. 5233.362US1), which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to drill rigs. More particularly, the present disclosure relates to tubular elevators.

BACKGROUND

The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventor, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

Operating a drill rig can involve a range of activities, such as drilling wells, installing well casings, tripping of the drill string (e.g., during which drill pipes are lowered into (tripping in (e.g., running into hole (RIH))) or pulled out of (tripping out (e.g., pulling out of hole (POOH))) a well), etc. A tubular elevator can be used to grip a drill pipe, such as to suspend a drill string or a pipe stand that is being added or removed from a drill string. A tubular elevator can be suspended from a traveling block of a drill rig, and can be configured to impinge on a tubular to support the tubular from the drill rig mast. The tubular elevator can be manually engaged or disengaged. During drilling operations, a variety of pipe sizes can be used. Moreover, drill collar can have a larger diameter than drill pipe even though they each form a part of the same drill string. Separate, differently sized, tubular elevators or parts (e.g., size components) may need to be used (e.g., during various operations) to accommodate the different sizes.

SUMMARY

In an example, a tubular elevator for a drill rig can include a plurality of size adjusting systems radially arranged about a housing of the tubular elevator and which can be configured to cooperate to adjust a diameter of a through opening of the tubular elevator to accommodate various tubular sizes. The tubular elevator can also include a slip component which can include a wedge arranged on a radially inner portion of each of the size adjusting systems and which can be configured to cooperate to further constrict the diameter of the through opening when a tubular can be suspended by the tubular elevator.

In an example, a tubular elevator for a drill rig can include two or more slip assemblies, arranged around a perimeter of a housing of the tubular elevator, where one or more of the slip assemblies can include an outer wedge, generally fixed relative to the housing, where a radially inward portion of the outer wedge can include a first inclined plane facing radially inward, where a bottom portion of the first inclined plane can be radially inward compared to a top portion of the first inclined plane. The tubular elevator can also include an intermediate wedge, where a radially outward portion of the intermediate wedge can be slidably engaged with the first inclined plane, where the intermediate wedge can move towards a center axis of a through opening of the tubular elevator when the intermediate wedge slides downward, where a radially inward portion of the intermediate wedge can include a second inclined plane facing radially inward, where a bottom portion of the second inclined plane can be radially inward compared to a top portion of the second inclined plane. The tubular elevator can also include an inner wedge, where a radially outward portion of the inner wedge can be slidably engaged with the second inclined plane, where the inner wedge can move towards the center axis of the through opening when the inner wedge slides downward.

In an example, a method of using a tubular elevator can include opening one or more elevator doors of the tubular elevator, passing a tubular laterally into a through opening of the tubular elevator through the elevator doors while the tubular elevator can be in a retracted position, and closing the one or more elevator doors. The method can also include engaging three slip assemblies of the tubular elevator with the tubular, centering the tubular within the through opening, and transferring a weight of the tubular to the tubular elevator.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which may not be drawn to scale, like numerals may describe substantially similar components throughout one or more of the views. Like numerals having different letter suffixes may represent different instances of substantially similar components. The drawings illustrate generally, by way of example but not by way of limitation.

FIG. 1 shows an example of portions of a drill rig including a tubular elevator.

FIG. 2 shows a perspective view of a tubular elevator suspended from a coupling.

FIG. 3 shows a perspective view of the tubular elevator of FIG. 2 in a closed condition.

FIG. 4 shows a cross-sectional view of an example of a slip assembly of the tubular elevator of FIG. 3.

FIG. 5 shows a cross-sectional view of an example of the slip assembly of FIG. 4 with the size adjusting system configured for a smaller tubular size as compared to FIG. 4.

FIG. 6 shows a cross-sectional view of an example of the slip assembly of FIG. 4 with the size adjusting system in the same position as FIG. 5 and with the slip component further constricting the through opening.

FIG. 7 shows a perspective view of an example of the tubular elevator of FIG. 3 with the elevator doors open.

FIG. 8 shows a top view of the engagement arms of the inner wedge of FIG. 4.

FIG. 9 shows a top view of the engagement arms of the inner wedge of FIG. 4.

FIG. 10 shows a diagram depicting an example of portions of a method of operating a tubular elevator.

DETAILED DESCRIPTION

A tubular elevator that can handle a range of tubular sizes (e.g., drill collar, drill pipe, well casing) can provide one or more benefits such as a reduction in human contact with the drilling process (e.g., any operation undertaken using a drilling rig, such as tripping, increasing a size or depth of a well bore, etc.), a reduction in human physical exertion during drilling, or an increase in the speed of operation of a drill rig. These benefits can arise because the tubular elevator does not need to be swapped out or adjusted to handle a range of tubular sizes. Additionally, a tubular elevator that is at least partially automated can provide one or more benefits, such as a reduction in human contact with the drilling process, a reduction in human physical exertion during drilling, an increase in the speed of operation of a drill rig, or an increase or other adjustment of the precision of the tubular elevator. In some examples, the tubular elevator can be operated manually, by another power source, or both. In some examples, the tubular elevator can provide position feedback, which can include an indication of whether or not a tubular is engaged with the tubular elevator. In some examples, the tubular elevator can grip a range of tubulars (e.g., range of tubular configurations, range of tubular sizes), such as without having to change size components (e.g., slips, inserts). In some examples, the tubular elevator can be at least partially automated (e.g., capable of being controlled remotely), which can help to remove the need for personnel to be near the center of the drill floor (e.g., in the red zone) or in a position to operate the tubular elevator manually (e.g., near a fingerboard).

Turning now to FIG. 1, a drill rig 100 of the present disclosure is shown. The drill rig 100 may be configured for onshore oil drilling in some embodiments. However, in other embodiments, other drilling rigs of the present disclosure may be configured for other drilling operations, including offshore drilling. The drill rig 100 may be configured to be a mobile or stationary rig. The drill rig 100 may generally have a drill floor 102, a mast 104, and a pipe handling system.

The drill floor 102 may include a platform positioned above or over a well and supported by a support structure 103. As shown, the drill floor 102 may be configured to provide a working space for drilling operations and/or a storage space for equipment and drill pipe. The drill floor 102 may have an opening arranged at or near well center (e.g., the well access hole 122) for accessing the well during drilling or tripping operations.

The mast 104 may extend from the drill floor with a height suitable for accommodating and/or building single, double, triple, quadruple, or other sized drill pipe stands. For example, the mast 104 may have a height of up to 50 feet, 100 feet 150 feet, 200 feet, or more. In other embodiments, the mast 104 may have any other suitable height or height range.

The lifting system may be configured for supporting the load of a tubular (e.g., pipe stand, drill string) during drilling, tripping in, tripping out, and/or other pipe handling operations. A tubular elevator 120 configured for coupling to a drill pipe may extend from the traveling block 118. In some embodiments, the tubular elevator 120 may be incorporated into a top drive, which may be coupled to the traveling block 118 via a hook dolly or the tubular elevator 120 may be more directly coupled to the traveling block 118 via a hook dolly. In either case, the traveling block 118 may be configured to raise and lower the tubular elevator 120, so as to raise and lower a length or stand of pipe, between the drill floor 102 and the crown block. The traveling block 118 may include one or more sheaves through which the main drill line may be reeved. The use of a tubular elevator of the present disclosure is believed to apply, at least in part, to any drill rig configuration, and is not limited to the drill rig shown in FIG. 1.

The drill rig 100 can also include a rig floor slip 130. The rig floor slip 130 may be arranged in or on the drill floor 102. For example, the rig floor slip 130 can be positioned in the well access hole 122. The well access hole 122 can be an opening (e.g., a hole) of any shape in the drill floor 102. During operation of the drill rig, operators may insert, feed, or otherwise pass a tubular 140 through the rig floor slip 130, the well access hole 122, or both.

FIG. 2 shows a perspective view of a tubular elevator 120 suspended from a coupling 206. FIG. 2 shows that the tubular elevator 120 can be connected to the coupling 206 by a first link 202 and a second link 204. The first link 202 can connect to a first link connection point 208 of the tubular elevator 120. The second link 204 can connect to a second link connection point 210 of the tubular elevator 120. In an example, the tubular elevator 120 can include other means for suspension than the first link connection point 208 and the second link connection point 210. The coupling 206 can be coupled to the traveling block 118. In an example, the coupling 206 can be a portion of a top-drive system.

In an example, the tubular elevator 120 need not be coupled to a traveling block and/or used with a top-drive system. For example, the tubular elevator 120 can be coupled to a robot (e.g., a robotic arm, an at least partially autonomous system), which can lift and/or guide pipes.

FIG. 3 shows a perspective view of the tubular elevator 120 of FIG. 2. The tubular elevator 120 can be configured to grasp one or more cylindrical objects, such as a tubular (e.g., a drilling pipe, a drill casing, a pipe string, a drill string, or any number of tubulars employed in operations on a drill rig). The tubular elevator 120 can be configured to carry a portion or all of the weight of the tubular, such as when the tubular is released from a rig floor slip, which can transfer the weight (e.g., the load) of the tubular to the tubular elevator 120. The tubular elevator 120 can include two or more slip assemblies 330. The slip assemblies 330 (e.g., elevator slip assemblies) can be arranged around a perimeter of a through opening 334 of the tubular elevator 120. The tubular elevator 120 can also include a housing 332 (e.g., an outer load-holding body), such as can be configured to interface with the first link connection point 208, the second link connection point 210, and the slip assemblies 230.

The tubular elevator 120 can include two slip assemblies 330, three slip assemblies 330, four slip assemblies 330, five slip assemblies 330, six slip assemblies 330 (e.g., as shown in FIG. 3), seven slip assemblies 330, eight slip assemblies 330, or nine or more slip assemblies 330. The slip assemblies 330 can be equally spaced radially around the perimeter of the tubular elevator 120 (e.g., three slip assemblies 120 degrees apart, six slip assemblies 60 degrees apart), or the slip assemblies 330 can be distributed radially in any other fashion.

A slip assembly 330 can include a size adjusting system and a slip component. The tubular elevator can include a plurality of slip assemblies 330 (e.g., a plurality of size adjusting systems, each with a corresponding slip component), which can be radially arranged about the housing 332 of the tubular elevator 120. The size adjusting systems can be configured to cooperate to adjust the diameter of a through opening 334 (e.g., the diameter formed by the radially inner most portion of the plurality of slip components). The plurality of size adjusting systems can help allow the tubular elevator 120 to accommodate various tubular sizes. The slip component can include a wedge arranged on a radially inner portion of each of the size adjusting systems. The slip components can be configured to cooperate to further constrict the diameter of the through opening when a tubular is suspended by the tubular elevator 120.

The tubular elevator 120 can also include one or more elevator doors 304 and one or more hinges 302. The elevator doors 304 can be included in or form a portion of the housing 332. Respective hinges 302 can be coupled to respective ones of the elevator doors 304. The hinges 302 can be configured to let the elevator doors 304 pivot relative to the housing 332, which can include pivoting radially outward, for example, about a longitudinally extending axis. In an example, a slip assembly 330 can be mounted on an elevator door 304. The elevator doors 304 can be coupled to a system that controls the position of the elevator doors (not shown). For example, an automated system can be configured to open and/or close the elevator doors 304. In an example, the elevator doors 304 can be opened and/or closed manually. There can be a latch or other locking mechanism (not shown) configured to hold the elevator doors 304 in a closed position, an open position, or both.

FIG. 4 shows a cross-sectional view of an example of a slip assembly 330 of the tubular elevator 120 of FIG. 3. In the example of FIG. 4, the slip assembly 330 is in the retracted (e.g., fully retracted) position. FIG. 4 includes an arrow indicating the radially inward direction. The slip assembly 330 can be configured to one or more of (1) clamp or release a tubular, such as at least partially automatically (e.g., at the command of a processor or other controller) or (2) adjust a size of tubular that the tubular elevator is configured to engage with. In an example, the slip assembly 330 need not be automated, and may be mechanical in nature (e.g., only mechanical clamping, only mechanical operation (e.g., manual operation)). The slip assembly 330 can be configured such that the slip assembly 330 clamps the tubular with a force that increases as a weight of the tubular carried by the tubular elevator 120 increases (e.g., a force proportional to the weight of the tubular). The slip assembly 330 can include an outer wedge 410, an intermediate wedge 420, and an inner wedge 430. The outer wedge 410 and the intermediate wedge 420 can be included in the size adjusting system. The inner wedge 430 can be included in the slip component.

The outer wedge 410, can be generally fixed relative to the housing 332. For example, a radially outer portion of the outer wedge 410 can be fixed to the housing 332. In the example of FIG. 4, the housing 332 may include the outer wedge 410 (e.g., the outer wedge 410 need not be a separate component from the housing). For example, respective portions of the housing 332 may define the outer wedge 410 for respective ones of the slip assemblies 330. The outer wedge 410 can be configured to provide a mounting connection for the slip assembly 330, and can be configured to provide a surface for the intermediate wedge 420 to interface with. A radially inward portion of the outer wedge 410 can include a first inclined plane 414 facing radially inward (e.g., the open face of the first inclined plane 414 is oriented at least partially towards the through opening 334, such as directly facing the through opening 334, or at an angle of less than 90 degrees from the radially inward axis). A bottom portion of the first inclined plane 414 can be radially inward compared to a top portion of the first inclined plane 414 (e.g., the first inclined plane 414 is facing upward and sloping radially inward). The outer wedge 410 (e.g., the housing 332) can be one piece of material (e.g., a cast or machined part), or can include two or more parts fastened together.

The intermediate wedge 420 can be configured to interface with the outer wedge 410. Together, the portions of the outer wedge 410 (e.g., all of the outer wedge 410), portions of the intermediate wedge 420 (e.g., all of the intermediate wedge 420), and optionally one or more other components can form a size adjusting system. The size adjusting system can be configured to adjust a size of tubular that the tubular elevator 120 is configured to engage with (e.g., adjusting a size of the opening formed by the plurality of slip assemblies 330), engage or release a tubular (e.g., by moving the slip assembly 330 into or out of contact with the tubular), or both. A radially outward portion 422 of the intermediate wedge 420 can be slidably engaged with the first inclined plane 414. The size adjusting system can be configured such that the intermediate wedge 420 moves towards a center axis of the through opening 334 when the intermediate wedge 420 slides downward, such as due to the configuration of the first inclined plane 414. This motion towards the center of the through opening 334 can help to provide one or more functions of the size adjusting system, such as adjusting a diameter of the through opening 334 or engaging and releasing a tubular. The intermediate wedge 420 can be one piece of material (e.g., a cast or machined part), or can include two or more parts fastened together.

A radially inward portion of the intermediate wedge 420 can include a second inclined plane 424 facing radially inward. A bottom portion of the second inclined plane 424 can be radially inward compared to a top portion of the second inclined plane.

The slip assembly 230 can also include one or more actuators 412, such as can form a portion of the size adjusting system. An actuator 412 can be configured to extend and retract longitudinally (e.g., a linear actuator). The actuator 412 can include a hydraulic or pneumatic cylinder, a screw drive, a rack/pinion, an electrical cylinder, a linear motor, or another type of linear actuator. A first end of the actuator 412 can be coupled to the outer wedge 410 and a second end of the actuator 412 can be coupled to the intermediate wedge 420. In an example, the first end of the actuator 412 can be coupled to the housing 332. The actuator 412 can be configured to adjust a position of the intermediate wedge 420 along the first inclined plane 414 of the outer wedge 410, such as to adjust the size adjusting system. The actuator 412 can be positioned between the outer wedge 410 and the intermediate wedge 420, which can include being positioned within an actuator cavity of the intermediate wedge 420, the outer wedge 410, or both. In an example, the slip assembly 330 can include two actuators 412. The actuators 412 can be positioned on opposite radially tangential sides of the slip assembly 330. In this example, the actuators 412 need not be positioned in an actuator cavity. In an example, the actuator 412 can be positioned between the first inclined plane 414 and the radially outward portion 422.

The outer wedge 410, the intermediate wedge 420, or both, can include one or more features configured to keep the first inclined plane 414 from separating from the radially outward portion 422, such as a retaining groove 416, retaining guides 436, or both. The intermediate wedge 420 can include the retaining groove 416. The outer wedge 410 can include the retaining guides 436. The retaining guides 436 can be attached to or form a part of the outer wedge 410. For example, the retaining guides 436 can be attached to the outer wedge 410 using a plurality of fasteners. The retaining groove 416 can be integral to the intermediate wedge 420 (e.g., machined into the intermediate wedge 420, as shown in FIG. 4), or can be a separate component fastened to the intermediate wedge 420 using one or more fasteners. The retaining guides 436 can be configured to interface with the retaining groove 416, such as to limit radially inward motion of the intermediate wedge 420 relative to the outer wedge 410, radially tangential (e.g., lateral) motion of the intermediate wedge 420 relative to the outer wedge 410, or both. In an example, the retaining guides 436 can be substantially “T-shaped” when viewed along the axis of the first inclined plane 414. The retaining groove 416 can have a corresponding “t-shaped” profile. This can help to allow the intermediate wedge 420 to be able to translate along the first inclined plane 414, without separating radially or tangentially from the first inclined plane 414.

The inner wedge 430 can form a portion or all of a slip component. The slip component can be configured to further constrict a diameter of the through opening 334 of the tubular elevator 120 when a tubular is suspended by the tubular elevator 120. The inner wedge 430 can be configured to interface with the intermediate wedge 420. A radially outward portion 432 of the inner wedge can be slidably engaged with the second inclined plane 424. The inner wedge 430 can be configured to move towards the center axis of the through opening 334 when the inner wedge 430 slides downward. The inner wedge 430 and the intermediate wedge 420 can be configured so that the second inclined plane 424 does not separate from the radially outward portion 432 (e.g., similarly to the intermediate wedge 420 and the outer wedge 410). The inner wedge 430 can be one piece of material (e.g., a cast or machined part), or can include two or more parts fastened together.

A radially inner surface 434 of the inner wedge 430 (e.g., the slip component) can be configured to engage with a tubular. The radially inner surface 434 can include teeth or other texture to increase or otherwise tailor a friction or grip force against the tubular. The radially inner surface 434 can include a curvature when viewed from above or below (e.g., as discussed with more detail with respect to FIGS. 8-9) to provide a larger area of contact with the tubular. In an example, the radially inner surface 434 can include one or more alloy strips (e.g., CuNiAl), which can be configured to be wear resistant, provide a specified level of friction, or both. For example, the alloy strips can provide a replaceable wear surface. The tubular elevator 120 can be configured to engage with a range of tubular sizes ranging from at least 1⅛ inches (e.g., the tubular sizes that can be engaged span at least 1⅛ inches in diameter), at least two inches, at least four inches, at least six inches, at least eight inches, or at least 12 inches. In an example, the tubular elevator 120 can engage with a range including a nominal size down to a smaller size (e.g., having a range of 4″ and a set nominal of 14″ grips from 14″ down to 10,″ such as without size component swap out). In an example, the tubular elevator 120 (e.g., including the slip assemblies 330) can be configured so that the radially inner surface 434 of the inner wedge 430 is generally parallel to the tubular across the range of tubular sizes. In an example, the tubular elevator 120 can be configured to engage with a mix of casing sizes, for example, a 9⅝ inch casing as well as a 10¾ inch thick wall casing.

In an example, one or more portions of the slip assembly 330 can be replaced to accommodate a different range of tubular sizes. For example, one configuration of the tubular elevator 120 can accommodate tubulars from 3 and ⅛ inch to 7 and ⅝ inch (e.g., measured in diameter of the outer surface of the tubular). The tubular elevator 120 can be reconfigured to accommodate a range from 5 and ½ inch to 10 inch or a range from 9 and ½ inch to 14 inch. For example, one or more of the outer wedge 410, the intermediate wedge 420, or the inner wedge 430 can be exchanged for a corresponding outer wedge 410, intermediate wedge 420, or inner wedge 430 of a different size. In an example, the entire slip assembly 330 can be replaced. In an example, the outer wedge 410 and the intermediate wedge 420 can be reused, and the inner wedge 430 can be replaced. In an example, the size adjusting system can be replaced, and the inner wedge 430 can be reused. In an example, the housing 332 is used across multiple tubular size ranges. In an example, the housing 332 is replaced to accommodate one or more tubular size ranges. In an example, the entire tubular elevator 120 can be replaced to accommodate a different tubular size range. In an example, the entire tubular elevator 120 can be replaced, such as to accommodate a different tubular size or range of tubular sizes.

In an example, one or more portions of the tubular elevator 120 can be configured differently. For example, the size adjusting component of the tubular elevator 120 can include a hydraulic cylinder that is faced generally radially inward. The radially outward portion of the hydraulic cylinder can be mounted to the housing 332. The inner wedge 430 or the intermediate wedge 420 can be mounted on the radially inward portion of the hydraulic cylinder. The hydraulic cylinder can be configured to adjust a size of the through opening. The hydraulic cylinder can be configured to carry a portion of the weight of the tubular (e.g., the hydraulic cylinder is braced to be substantially rigid when the downward load of the tubular is applied to the inner wedge 430). In other examples, a worm drive may be used in lieu of a hydraulic cylinder or another non-reversing device may be provided.

In an example, the housing 332 can be a closed (e.g., continuous) ring. In an example, the housing 332 can be a hinged split ring (e.g., as shown and discussed with respect to FIGS. 7-8), such as can allow for removing a tubular from the through opening 334 laterally (e.g., while a tubular is passing through or arranged within the tubular elevator 120).

FIG. 5 and FIG. 6 show a cross-sectional view of an example of portions of a slip assembly 330. In use and operation of the tubular elevator 120, one or more of the plurality of size adjusting systems can be configured to travel between a retracted position, where the respective slip components need not be contacting the tubular, and an engaged position, where the respective slip components can be contacting the tubular. In the example of FIG. 5 and FIG. 6, the slip assembly 330 can be in the engaged position. For example, the actuator 412 can be configured to control a position of the intermediate wedge 420 along the first inclined plane 414. The actuator 412 can control the slip assembly 330 between a retracted position, where the slip assembly may not be contacting a tubular, and an engaged position, where the slip assembly can be contacting the tubular. In an example, the movement of the size adjusting systems can serve the function of engaging and disengaging the tubular, accommodating various tubular sizes, or both.

FIG. 4 shows the slip assembly 330 in a retracted position, which can include a fully retracted position. FIG. 5 shows the slip assembly 330 in an engaged position, which can include an engaged position at the end of a configured travel of the size adjusting system. In an example, the slip assembly 330 can contact the tubular before reaching the end of travel. The actuator 412 can apply a force against the tubular (e.g., an inward force). In an example, the force provided by the actuator 412 can be small compared to the force caused by the operation of the slip component, such as can include one half as large or less, one tenth as large or less, or one hundredth as large or less.

FIG. 6 shows an example where the size adjusting system is engaged and a portion of the weight of the tubular has been shifted to the tubular elevator 120. FIG. 6 shows that the inner wedge 430 has moved downward, applying an increased inward force on the tubular, such as can increase a frictional force between the inner wedge 430 and the tubular, which can help allow the tubular to be suspended by the tubular elevator 120. FIG. 6 shows that the intermediate wedge 420 has not moved from the position shown in FIG. 5. In an example, the intermediate wedge 420 can move slightly or significantly in response to the tubular loading the tubular elevator 120.

The inner wedge 430 can be biased in an upward direction along the second inclined plane 424, such as by a spring (not shown). The spring can return the inner wedge 430 to or towards the initial position when the tubular elevator 120 is not suspending the tubular. From the initial position, the inner wedge 430 can be configured to engage the tubular, such as to provide a full clamping travel of the inner wedge 430. The bias force of the spring can be configured to be overcome by the weight of the tubular (e.g., the spring can support the weight of the inner wedge 430 but not the weight of the inner wedge 430 in addition to the downward force applied by the tubular) when the weight of the tubular is transferred to the tubular elevator 120.

FIG. 6 shows that the inner wedge axis 442 of the second inclined plane 424 relative to the center axis 440 of the through opening 334 can form a second angle 444. The intermediate wedge axis 446 of the first inclined plane 414 relative to the center axis 440 can form a first angle 448. In an example, the second angle 444 is less than the first angle 448 (e.g., as shown in FIG. 6). In an example, the second angle 444 is between 9 and 14 degrees, or between 10 and 12 degrees, or 11 degrees. In an example, the first angle 448 is between 14 and 35 degrees, or between 20 and 30 degrees, or between 23 and 28 degrees, or 25 degrees. In an example, the second angle 444 is 10 degrees and the first angle 448 is 20 degrees.

When a portion of the weight of the tubular is suspended by the slip assembly 330, there can be a generally upward force (e.g., acting on an axis between the inner wedge axis 442 and the intermediate wedge axis 446) acting on the intermediate wedge 420 as a result of the configuration of the slip assembly 330. The upward force on the intermediate wedge 420 can be caused by the differing angles of the first inclined plane 414 and the second inclined plane 424. In an example, the slip assembly 330 can be configured such that the frictional forces acting on the intermediate wedge 420 (e.g., the frictional force acting to hold the intermediate wedge 420 stationary) exceed the upward force acting on the intermediate wedge 420. For example, the interfaces between the outer wedge 410 and the intermediate wedge 420, the intermediate wedge 420 and the inner wedge 430, or both, can be configured to increase a frictional force (e.g., using surface roughness, using materials with a large coefficient of friction). In an example, a force from one or more actuators 412 can at least partially offset (e.g., completely offset, less than completely offset) the upward force acting on the intermediate wedge 420.

In an example, the tubular elevator 120 can be configured to engage with a portion of a tubular that has a consistent diameter (e.g., a cylindrical portion). In an example, the tubular elevator 120 can be configured to engage with a tubular that has a consistent diameter (e.g., a consistent diameter across the entire tubular, a well casing). For example, the tubular elevator 120 may be able to engage with a tubular without requiring the outer surface of the tubular to have a contour (e.g., engaging with a uniform portion of the tubular, as opposed to an expanded tool end).

FIG. 7 shows a perspective view of an example of the tubular elevator 120 of FIG. 3 with the elevator doors 304 open. FIG. 7 shows that the elevator doors 304 have pivoted radially outward on hinges 302, creating a lateral opening in the tubular elevator 120. This can allow a tubular to be passed laterally into the through opening 334, such as in a way that would contact the housing 332 if the elevator doors 304 were not open. For example, if the tubular elevator 120 did not include elevator doors 304, a tubular may need to be passed into the through opening 334 longitudinally from the top and/or bottom.

FIGS. 8-9 show a close up top view of the inner wedge 430 of FIG. 4. FIG. 8 shows that the inner wedge 430 can include two or more engagement arms 902. The engagement arms can include engagement faces 906, which can form the radially inner surface 434. The engagement arms 902 can be mounted on hinges 908. The engagement arms 902 can be configured to rotate about the hinges 908. In an example, the rotation of the engagement arms 902 about respective hinges 908 can be limited to a specified range (e.g., within 10 degrees of a neutral position, within 15 degrees of a neutral position). The rotation of the engagement arms 902 can help to allow the engagement faces 906 to be substantially tangential to a surface of the tubular (e.g., the engagement face 906 forms a tangent, or is substantially tangential, at the point of intersection with the tubular) across a range of tubular sizes.

FIG. 8 shows that a first angle 904 can be formed by the engagement arms 902. The first angle 904 can help to allow the engagement faces 906 to be substantially tangential to the surface of a tubular with a first radius 910. FIG. 9 shows that a second angle 912 can be formed by the engagement arms 902 when engaging a tubular with a second radius 914. The second angle 912 can help to allow the engagement faces 906 to be substantially tangential to the surface of a tubular with the second radius 914. The second radius 914 can be larger than the first radius 910. The second angle 912 can be smaller than the first angle 904.

In an example, the angle formed by the engagement arms 902 is configured to be adjusted by a force from a tubular engaging with the engagement arms 902. For example, the engagement arms 902 can be biased (e.g., spring biased) towards a neutral position, which may result in the engagement faces 906 being substantially tangential to a tubular with a specified radius. When a tubular with a radius other than the specified radius is engaged, the biasing force may be overcome (e.g., by the force of the tubular pressing against the engagement faces 906) and the engagement arms 902 may pivot to a position where the engagement faces 906 are substantially tangential to the tubular surface.

FIG. 10 shows a diagram depicting an example of portions of a method 1000 of operating a tubular elevator (e.g., the tubular elevator 120). At step 1002, one or more elevator doors (e.g., elevator doors 304) of the tubular elevator can be opened. This operation can be performed by an actuator, or can be performed manually.

At step 1004, a tubular can be passed laterally into a through opening of the tubular elevator through the elevator doors, such as while the tubular elevator is in a retracted position. For example, the tubular elevator may be passed laterally onto a drill string or a pipe stand.

At step 1006, one or more elevator doors can be closed. In an example, step 1006 can include locking one or more of the elevator doors, such as after they have been closed. For example, a latching mechanism can be engaged to disable one or more of the hinges 302 or prevent the elevator doors 304 from moving relative to each other. This can help to increase a load carrying capacity of the tubular elevator 120. For example, the slip assemblies 330 can apply an radially outward force, such as when supporting a portion (e.g., all) of the weight of a tubular or tubular string. This radially outward force can force the elevator doors 304 radially outward, and the latching mechanism can help to resist this outward force.

At step 1008, two or more slip assemblies (e.g., three) of the tubular elevator can be engaged with the tubular. For example, two opposing slip assemblies can move to contact the tubular, or three radially spaced slip assemblies can move to contact the tubular.

At step 1010, the tubular can be centered within the through opening of the tubular elevator. The tubular can be centered in the through opening using the slip assemblies engaged in step 1008. In an example, centering the tubular within the well access hole can include monitoring respective positions of the slip assemblies. For example, a position of one or more actuators can be monitored, such as through position feedback from a sensor on the actuator. In an example, a servo technique can be used, which can enable position control of the actuator. The servo technique can include a feedback system configured to monitor a position of the actuator and drive the actuator towards a specified position (e.g., a new position, maintaining the same position). Monitoring a position of the slip assemblies (e.g., the three slip assemblies) can include monitoring respective actuators of the three slip assemblies, such as the actuators 412. In other examples, a leveling beam can be used to monitor the position of the slip assemblies.

Centering the tubular can also include adjusting the two or more slip assemblies so that the tubular is centered within the well access hole. For example, if one slip assembly is determined to be in a different position from one or more other slip assemblies, the slip assemblies can be adjusted to approximately match positions. In an example, position monitoring may not be used when three slip assemblies are used to center the tubular.

In an example, centering the tubular within the through opening can include one or more of engaging the three slip assemblies so that each of the slip assemblies starts a specified distance from a center axis of the through opening or travels at a same rate toward the center axis of the well access hole. For example, the actuators 412 can be configured to all travel at a constant rate such as using one or more of proportional valves, flow divertors, or a servo technique. The slip assemblies 330 can start from the fully retracted position (e.g., the same position). In an example, the slip assemblies 330 can start from a preset position, such as relative to the pipe size to be engaged, such as can reduce the closing or opening cycle time. In this example, because the slip assemblies 330 start in the same position and travel at the same rate (e.g., due to proportional valves and/or position feedback), their positions can continue to match, which can center the tubular. In an example, the method 1000 can include engaging one or more additional slip assemblies following centering the tubular within the well access hole. For example, three slip assemblies can be used to center the tubular, and then three or more additional slip assemblies can be engaged with the centered tubular. In an example where two or more actuators share a hydraulic power supply, the pressure in all of the actuators can match, which can result in a force in all actuators matching. When using proportional valves, the pressure in one or more actuators can differ from a pressure in one or more other actuators. When using a servo technique, respective actuators can travel to their specified position, such as can include traveling to their respective positions using different force levels (e.g., the forces may not match between two or more actuators).

At step 1012, a weight of the tubular can be transferred to the tubular elevator. For example, the tubular elevator 120 can be lifted by the traveling block 118, transferring a weight of a pipe stand from the drill floor to the tubular elevator 120. In an example, the rig floor slip 130 can be disengaged, transferring a weight of a drill string to the tubular elevator 120. In an example, lifting the tubular elevator 120 (e.g., using the traveling block 118) can transfer a weight of a drill string to the tubular elevator 120 (e.g., by engaging the slip components), disengage a rig floor slip 130, or both.

The shown order of steps is not intended to be a limitation on the order the steps are performed in. In an example, two or more steps may be performed simultaneously or at least partially concurrently.

The following, non-limiting examples, detail certain aspects of the present subject matter to solve the challenges and provide the benefits discussed herein, among others.

EXAMPLES

Example 1 is a tubular elevator for a drill rig, the tubular elevator comprising: a plurality of size adjusting systems radially arranged about a housing of the tubular elevator and configured to cooperate to adjust a diameter of a through opening of the tubular elevator to accommodate various tubular sizes; and a slip component comprising a wedge arranged on a radially inner portion of each of the size adjusting systems and configured to cooperate to further constrict the diameter of the through opening when a tubular is suspended by the tubular elevator.

In Example 2, the subject matter of Example 1 optionally includes wherein each of the plurality of size adjusting systems are configured to travel between a retracted position, wherein the respective slip components are not contacting the tubular, and an engaged position, wherein the respective slip components are contacting the tubular.

In Example 3, the subject matter of Example 2 optionally includes wherein the movement of the size adjusting systems serves the function of both: engaging and disengaging the tubular; and accommodating various tubular sizes.

In Example 4, the subject matter of any one or more of Examples 1-3 optionally include the housing, wherein a radially inner portion of the housing is configured to engage with a radially outer portion of the size adjusting systems, the housing comprising: one or more hinges, configured to allow one or more elevator doors in the housing to open to allow a tubular to be passed into the through opening laterally.

In Example 5, the subject matter of Example 4 optionally includes the housing comprising a latching mechanism, configured to hold the one or more elevator doors closed when the tubular elevator is engaged position with a tubular.

In Example 6, the subject matter of any one or more of Examples 4-5 optionally include wherein a radially outer portion of the housing is configured to engage with a pair of links of the drill rig.

In Example 7, the subject matter of any one or more of Examples 1-6 optionally include wherein a radially inner surface of the slip component is configured to engage with the tubular, wherein the tubular elevator is configured to engage with a range of tubular sizes spanning at least four inches.

In Example 8, the subject matter of Example 7 optionally includes wherein the radially inner surface of the slip component includes two engagement arms, wherein an angle formed by the engagement arms is configured to be adjustable such that a face of the engagement arms is substantially tangential to a tubular surface across the range of tubular sizes.

In Example 9, the subject matter of Example 8 optionally includes wherein the angle formed by the engagement arms is configured to be adjusted by a force from a tubular engaging with the two engagement arms.

In Example 10, the subject matter of any one or more of Examples 1-9 optionally include the drill rig, the drill rig comprising: a traveling block supported by a mast, wherein the tubular elevator is connected to the traveling block by a pair of links.

In Example 11, the subject matter of any one or more of Examples 1-10 optionally include wherein the tubular elevator is configured to engage with a portion of a tubular that has a consistent diameter.

Example 12 is a tubular elevator for a drill rig, the tubular elevator comprising: two or more slip assemblies, arranged around a perimeter of a housing of the tubular elevator, each of the slip assemblies including: an outer wedge, generally fixed relative to the housing, wherein a radially inward portion of the outer wedge includes a first inclined plane facing radially inward, wherein a bottom portion of the first inclined plane is radially inward compared to a top portion of the first inclined plane; an intermediate wedge, wherein a radially outward portion of the intermediate wedge is slidably engaged with the first inclined plane, wherein the intermediate wedge moves towards a center axis of a through opening of the tubular elevator when the intermediate wedge slides downward, wherein a radially inward portion of the intermediate wedge includes a second inclined plane facing radially inward, wherein a bottom portion of the second inclined plane is radially inward compared to a top portion of the second inclined plane; and an inner wedge, wherein a radially outward portion of the inner wedge is slidably engaged with the second inclined plane, wherein the inner wedge moves towards the center axis of the through opening when the inner wedge slides downward.

In Example 13, the subject matter of Example 12 optionally includes wherein the slip assemblies comprise an actuator, wherein a first end of the actuator is coupled to the outer wedge and a second end of the actuator is coupled to the intermediate wedge, wherein the actuator is configured to control a position of the intermediate wedge along the first inclined plane between a retracted position, wherein the slip assembly is not contacting a tubular, to an engaged position, wherein the slip assembly is contacting the tubular.

In Example 14, the subject matter of Example 13 optionally includes a spring element, configured to bias the inner wedge in an upward direction along the second inclined plane.

In Example 15, the subject matter of any one or more of Examples 12-14 optionally include the housing, the housing comprising: one or more hinges, configured to allow one or more elevator doors in the housing to open to allow a tubular to be passed into the through opening laterally.

In Example 16, the subject matter of any one or more of Examples 12-15 optionally include wherein a radially inner surface of the inner wedge includes two engagement arms configured to engage with the tubular, wherein an angle formed by the engagement arms is configured to be adjustable such that a face of the engagement arms is substantially tangential to a tubular surface across a range of tubular sizes.

In Example 17, the subject matter of any one or more of Examples 12-16 optionally include wherein a second angle of the second inclined plane relative to the center axis of the through opening is less than a first angle of the first inclined plane relative to the center axis of the through opening.

In Example 18, the subject matter of Example 17 optionally includes wherein the second angle is between nine and fourteen degrees and wherein the first angle is between fourteen and thirty-five degrees.

In Example 19, the subject matter of any one or more of Examples 12-18 optionally include wherein the slip assemblies are configured such that frictional forces acting on the intermediate wedge exceed an upward force caused by differing angles of the first inclined plane and the second inclined plane.

Example 20 is a method of using a tubular elevator, the method comprising: opening one or more elevator doors of the tubular elevator; passing a tubular laterally into a through opening of the tubular elevator through the elevator doors while the tubular elevator is in a retracted position; closing the one or more elevator doors; engaging three slip assemblies of the tubular elevator with the tubular; centering the tubular within the through opening; and transferring a weight of the tubular to the tubular elevator.

In Example 21, the subject matter of Example 20 optionally includes wherein centering the tubular within the through opening includes: monitoring respective positions of the three slip assemblies; and adjusting the three slip assemblies so that the tubular is centered within the through opening.

In Example 22, the subject matter of Example 21 optionally includes wherein monitoring a position of the three slip assemblies includes monitoring respective actuators of the three slip assemblies.

In Example 23, the subject matter of Example 22 optionally includes wherein centering the tubular within the through opening includes engaging the three slip assemblies so that each of the slip assemblies starts a specified distance from a center axis of the through opening and travels at a same rate toward the center axis of the through opening.

In Example 24, the subject matter of any one or more of Examples 20-23 optionally include engaging one or more additional slip assemblies following centering the tubular within the through opening.

Example 25 is at least one machine-readable medium including instructions that, when executed by processing circuitry, cause the processing circuitry to perform operations to implement of any of Examples 1-24.

Example 26 is an apparatus comprising means to implement of any of Examples 1-24.

Example 27 is a system to implement of any of Examples 1-24.

Example 28 is a method to implement of any of Examples 1-24.

Each of the non-limiting aspects above can stand on its own or can be combined in various permutations or combinations with one or more of the other aspects or other subject matter described in this document.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific examples that may be practiced. These embodiments are also referred to herein as “examples.” Such examples may include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

All publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the terms “or” and “and/or” are used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The term “about,” as used herein, means approximately, in the region of, roughly, or around. When the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. In general, the term “about” is used herein to modify a numerical value above and below the stated value by a variance of 10%. In one aspect, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50% means in the range of 45%-55%. Numerical ranges recited herein by endpoints include all numbers and fractions subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.90, 4, 4.24, and 5). Similarly, numerical ranges recited herein by endpoints include subranges subsumed within that range (e.g., 1 to 5 includes 1-1.5, 1.5-2, 2-2.75, 2.75-3, 3-3.90, 3.90-4, 4-4.24, 4.24-5, 2-5, 3-5, 1-4, and 2-4).

Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Such instructions can be read and executed by one or more processors to enable performance of operations comprising a method, for example. The instructions are in any suitable form, such as but not limited to source code, compiled code, interpreted code, executable code, static code, dynamic code, and the like.

Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other examples may be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is to allow the reader to quickly ascertain the nature of the technical disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment. The scope of the examples should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.