ELEVATOR ROLLER INSERT SYSTEM

Abstract

A device, system, and/or method for reducing friction required to rotate a tubular within an elevator during the process of running tubulars in an oil and gas well are provided. An elevator roller insert may be used in conjunction with an elevator, such as a single joint elevator. Such an insert may comprise upper and lower rollers which are positioned on upper and lower roller sets or a combination roller set containing multiple upper and/or lower rollers. The result is the provision of a plurality of rollers which bear the weight of a tubular yet still allow the tubular to rotate rather freely, facilitating the maintenance of proper thread integrity of the connections while making up a stand to a string of tubulars as well as preventing the loss of resources due to galled or crushed threads or a tubing segment or stand falling to the rig floor.

Claims

1. An elevator roller system for a drilling rig, comprising: a tubular having a first outer diameter and a second outer diameter, wherein the first outer diameter is smaller than the second outer diameter; an elevator having: a first arm having an interior surface; a second arm having an interior surface, the first and second arms hingedly interconnected and rotatable between an open position and a closed position, wherein the interior surfaces of the arms form an aperture with a central axis in the closed position; a plurality of first rollers disposed in the interior surfaces of the first and second arms and positioned about the central axis of the aperture, wherein the plurality of first rollers forms an inner diameter; a plurality of second rollers disposed in the interior surfaces of the first and second arms and positioned about the central axis of the aperture, wherein the plurality of second rollers forms an inner diameter that is smaller than the second outer diameter of the tubular; and wherein the pluralities of first and second rollers are configured to contact the tubular when the arms are in the closed position and further wherein the tubular is capable of freely rotating relative to the elevator when the arms are in the closed position.

2. The elevator roller system of claim 1, wherein the rollers in the plurality of first rollers each have an axis oriented substantially perpendicular with the central axis of the aperture.

3. The elevator roller system of claim 1, wherein the rollers in the plurality of first rollers each have an axis oriented at a nonzero angle with the central axis, and the rollers in the plurality of second rollers each have an axis oriented substantially parallel with the central axis.

4. The elevator roller system of claim 1, wherein the rollers in the plurality of first rollers are each one of a thrust bearing, a radial bearing, and a cam follower roller, and wherein the rollers in the plurality of second rollers are each one of a thrust bearing, a radial bearing, and a cam follower roller.

5. The elevator roller system of claim 1, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers.

6. The elevator roller system of claim 5, wherein the inner diameter formed by the plurality of upper rollers is larger than the inner diameter formed by the plurality of lower rollers.

7. The elevator roller system of claim 1, wherein the rollers in the plurality of first rollers are arranged in a common plane, and wherein the rollers in the plurality of second rollers are arranged in a common plane.

8. The elevator roller system of claim 1, wherein the inner diameter formed by the plurality of first rollers and the inner diameter formed by the plurality of second rollers are identical.

9. The elevator roller system of claim 1, wherein the pluralities of first and second rollers are disposed in the interior surfaces of inserts configured to selectively interconnect to the interior surface of the first and second arms.

10. The elevator roller system of claim 1, wherein the second outer diameter of the tubular is an elevator upset area or coupling of the tubular, and wherein the first outer diameter of the tubular is a body of the tubular.

11. An elevator roller insert, comprising: an insert having an interior surface and an exterior surface, wherein the interior surface forms an aperture with a central axis, and wherein the exterior surface of the insert is configured to selectively interconnect to an interior surface of an elevator; a plurality of first rollers disposed on the interior surface of the insert and positioned about the central axis, wherein the plurality of first rollers forms an inner diameter, and the rollers in the plurality of first rollers are freely rotatable; a plurality of second rollers disposed on the interior surface of the insert and positioned about the central axis, wherein the plurality of second rollers forms an inner diameter, and the rollers in the plurality of second rollers are freely rotatable; and wherein the pluralities of first and second rollers are configured to contact a tubular and facilitate free rotation of the tubular relative to the elevator.

12. The elevator roller insert of claim 11, wherein the insert is comprised of a plurality upper roller sets and lower roller sets; further wherein the plurality of first rollers are disposed on the upper roller sets and the plurality of second rollers are disposed on the lower roller sets.

13. The elevator roller insert of claim 12, wherein each upper roller set is disposed between two lower roller sets and each lower roller set is disposed between two upper roller sets, wherein the plurality of upper and lower roller sets are disposed about the central axis.

14. The elevator roller insert of claim 11, wherein the elevator roller insert is comprised of at least one combination roller set, further wherein the combination roller set is comprised of a combination roller block and at least one upper roller and at least one lower roller.

15. The elevator roller insert of claim 11, wherein the rollers in the plurality of first rollers each have an axis oriented substantially perpendicular with the central axis.

16. The elevator roller insert of claim 11, wherein the rollers in the plurality of first rollers each have an axis oriented at a nonzero angle with the central axis, and the rollers in the plurality of second rollers each have an axis oriented substantially parallel with the central axis.

17. The elevator roller insert of claim 11, wherein the rollers in the plurality of first rollers are each one of a thrust bearing, a radial bearing, and a cam follower roller, and wherein the rollers in the plurality of second rollers are each one of a thrust bearing, a radial bearing, and a cam follower roller.

18. The elevator roller insert of claim 11, wherein the rollers in the plurality of first rollers are arranged in a common plane, and wherein the rollers in the plurality of second rollers are arranged in a common plane.

19. The elevator roller insert of claim 11, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers, and further wherein the inner diameter formed by the plurality of first rollers is larger than the inner diameter formed by the plurality of second rollers.

20. The elevator roller insert of claim 11, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers, and further wherein the inner diameter formed by the plurality of first rollers and the inner diameter formed by the plurality of second rollers are identical.

21. A method of assembling tubulars using an elevator, comprising: providing an elevator having: a first arm having an interior surface; a second arm having an interior surface, the first and second arms hingedly interconnected and rotatable between an open position and a closed position, wherein the interior surfaces of the arms form an aperture with a central axis in the closed position; a plurality of first rollers disposed in the interior surfaces of the first and second arms and positioned about the central axis of the aperture, wherein the rollers in the plurality of first rollers are freely rotatable; a plurality of second rollers disposed in the interior surfaces of the first and second arms and positioned about the central axis of the aperture, wherein the rollers in the plurality of second rollers are freely rotatable; positioning a first tubular in the aperture of the first and second arms of the elevator such that the first tubular contacts the pluralities of first and second rollers, the first tubular having a box end and a pin end, wherein the box end of the first tubular has an outer diameter that is greater than an inner diameter formed by the plurality of second rollers; and freely rotating the first tubular relative to the elevator and selectively interconnecting the pin end of the first tubular to a box end of a second tubular.

22. The method of claim 21, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers, and further wherein an inner diameter formed by the plurality of first rollers is larger than the inner diameter formed by the plurality of second rollers.

23. The method of claim 21, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers, and further wherein an inner diameter formed by the plurality of first rollers and the inner diameter formed by the plurality of second rollers are identical.

24. The method of claim 21, wherein the pluralities of first and second rollers are disposed in the interior surfaces of inserts configured to selectively interconnect to the interior surface of the first and second arms.

25. The method of claim 21, wherein the rollers in the plurality of first rollers are each one of a thrust bearing, a radial bearing, and a cam follower roller, and wherein the rollers in the plurality of second rollers are each one of a thrust bearing, a radial bearing, and a cam follower roller.

26. A method of assembling tubulars using an elevator, comprising: providing an elevator having: a plurality of first rollers positioned about a central axis of an aperture of the elevator, wherein the rollers in the plurality of first rollers are freely rotatable; a plurality of second rollers positioned about the central axis of the aperture of the elevator, wherein the rollers in the plurality of second rollers are freely rotatable; positioning at least one tubular in the elevator such that the at least one tubular contacts the pluralities of first and second rollers, wherein a box end of the at least one tubular has an outer diameter that is greater than an inner diameter formed by the plurality of second rollers; and freely rotating, by an operator, the at least one tubular relative to the elevator to start a selective interconnection between a pin end of the at least one tubular and a box end of another tubular.

27. The method of claim 26, wherein the at least one tubular is a plurality of tubulars.

28. The method of claim 26, wherein the operator freely rotates the at least one tubular using a strap wrench.

29. The method of claim 26, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers, and further wherein an inner diameter formed by the plurality of first rollers is larger than an inner diameter formed by the plurality of second rollers.

30. The method of claim 26, wherein the rollers in the plurality of first rollers are upper rollers, and wherein the rollers in the plurality of second rollers are lower rollers positioned below the upper rollers, and further wherein an inner diameter formed by the plurality of first rollers and an inner diameter formed by the plurality of second rollers are identical.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate certain embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures.

[0022] FIG. 1a is a section view of a single upper roller block in accordance with embodiments of the invention;

[0023] FIG. 1b is a section view of a single lower roller block in accordance with embodiments of the invention;

[0024] FIG. 2a is a section view of a single upper roller block utilizing a cam follower roller in accordance with embodiments of the invention;

[0025] FIG. 2b is a section view of a single lower roller block utilizing a cam follower roller in accordance with embodiments of the invention;

[0026] FIG. 3 is a top view of an elevator roller insert utilizing an arrangement of single upper and lower roller blocks in accordance with embodiments of the invention;

[0027] FIG. 4 is a top view of an elevator roller insert utilizing an arrangement of multiple roller blocks in accordance with embodiments of the invention; and

[0028] FIG. 5 is a section view of a segment of tubing having an integral (beveled) connection within the roller insert in accordance with embodiments of the invention;

[0029] FIG. 6 is a section view of a segment of tubing having a conventional (collared) connection within the roller insert in accordance with embodiments of the invention;

[0030] FIG. 7a is a top view of a single joint elevator encompassing an elevator roller insert in a closed position in accordance with embodiments of the invention; and

[0031] FIG. 7b is a top view of a single joint elevator encompassing an elevator roller insert in an open position in accordance with embodiments of the invention.

[0032] It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

[0033] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, and may be modified in numerous ways within the scope and spirit of the invention.

[0034] Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.

[0035] Various embodiments of the invention are described herein and as depicted in the drawings. It is expressly understood that although the figures depict tubulars, inserts, and elevators, the invention is not limited to these embodiments.

[0036] Now referring to FIG. 1a, an upper roller set 26 is provided with an upper roller 4 positioned within a recess of the upper roller block 2, the upper roller 4 having a rotational axis 6 about which the upper roller 4 rotates to accommodate tubulars being handled by an elevator. In some embodiments, upper roller 4 may comprise a combination of axial and thrust bearings encased within a roller housing and rotating about a central shaft 8. Also, as it can be appreciated by one skilled in the art, in certain embodiments, the types and sequence of bearings may be different than discussed herein to accommodate the different types of tubing and tubing connections being handled by an elevator. A plurality of upper roller sets 26 can form an elevator roller insert 30 (shown in FIG. 3 below) that bears the weight of a tubular yet still allows the tubular to rotate rather freely. To bear the weight of the tubular and to allow free rotation of the tubular, the upper roller 4 is configured to have a maximum operating weight and a maximum load rating. In some embodiments, the maximum operation weight for an upper roller 4 is 4,350 lbs and the maximum load rating is 6,300 lbs. It will be appreciated that in other embodiments, the maximum operation weight and the maximum load rating for an upper roller 4 may be greater or less than 4,350 lbs and 6,300 lbs, respectively.

[0037] In the embodiment shown in FIG. 1a, the rotational axis 6 of the upper roller 4 is offset in a transverse direction from a central axis 8 of a complete elevator roller insert 22 (shown in FIGS. 3 and 4 below). Also, rotational axis 6 of the upper roller 4 may be offset from the vertical by an upper roller angle 10. In various embodiments, the upper roller angle 10 is approximately 0, 5, 12 or 18 degrees to match common tubular connection angles. In other embodiments, the upper roller angle 10 ranges from 0 to 90 degrees.

[0038] In some embodiments, the upper roller set 26 is also comprised of a connection 12 which allows the roller block to be fixed to the elevator in some abutting fashion. In some embodiments this connection will be a dovetail type connection. In other embodiments the connection type may match that of the elevator that the inserts will be used in.

[0039] Now referring to FIG. 1b, a lower roller set 28 is provided with a lower roller 16 positioned within a recess of the lower roller block 14. The lower roller 16 has a rotational axis 18 about which the lower roller 16 rotates to prevent a tubular from binding against the elevator roller insert 30 should the elevator be tilted or off center. The lower roller 16 may comprise a combination of axial and thrust bearings encased within a roller housing and rotating about a central shaft 20. Also, as it can be appreciated, in certain embodiments, the types and sequence of bearings may be different than discussed here to accommodate the different types of tubing and tubing connections being handled by an elevator. In the embodiment shown in FIG. 1b, the rotational axis 18 of the lower roller 16 is substantially parallel with a central axis of the complete elevator roller insert 30 (shown in FIGS. 3 and 4 below), or a central axis of a roller set. However, in some embodiments, the rotational axis 18 of the lower roller 16 may form a lower roller angle similar to the upper roller angle 10. In various embodiments, the lower roller angle may be between approximately 0 and 90 degrees.

[0040] In some embodiments, the lower roller set 28 may also be comprised of a connection 12 which allows the roller block to be fixed to the elevator in some abutting fashion. In some embodiments this connection will be a dovetail type connection. In other embodiments the connection type will match that of the elevator that the inserts will be used in.

[0041] Now referring to FIG. 2a, some embodiments of the upper roller set 26 may utilize a cam follower roller 22 instead of an upper roller 4 with bearings as depicted in FIG. 1a. Cam follower rollers are well known to those skilled in the art, and an exemplary cam follower roller is disclosed by U.S. Pat. No. 4,152,953, which is incorporated herein in its entirety by reference. The cam follower roller 22 would be threaded or otherwise secured into the upper roller block 2 and would bear the weight of the tubular being handled by the elevator 40. The cam follower roller would be oriented along a rotational axis 6 similar to that of the upper roller 2 in FIG. 1a, and its utilization would also be similar.

[0042] Now referring to FIG. 2b, some embodiments of the lower roller block 14 may utilize a cam follower roller 24 instead of a lower roller 16 with bearings as depicted in FIG. 1b. The cam follower roller 24 would be threaded or otherwise secured into the lower roller block 14 and rotate to prevent a tubular from binding against an insert should the elevator be tilted or off center. In some embodiments, the cam follower roller is oriented along a rotational axis 18 similar to that of the lower roller in FIG. 1b, and its utilization would also be similar.

[0043] Now referring to FIG. 3, a combination of upper roller sets 26 and a combination of lower roller sets 28 may be combined to form an elevator roller insert 30. A plurality of upper roller blocks 2 are arranged about the central axis 8 of the elevator roller insert 22 to form the upper roller set 28, and similarly, a plurality of lower roller blocks 14 are arranged about the central axis 8 of the elevator roller insert 30 to form the lower roller set 28. The upper and lower roller sets 26, 28 may then combine to form a complete elevator roller insert 30. In some embodiments the upper rollers may be combined in the same block with the lower rollers (combination block 32) in a single or multiple block set as can be seen in FIG. 4. In other embodiments there may be no lower roller sets 28 included in the elevator roller insert 30.

[0044] The elevator roller insert 30 may comprise various numbers of upper roller sets 26 and lower roller sets 28. For example, in some embodiments, the elevator roller insert 30 comprises four upper roller sets 26 and four lower roller sets 28. It will be appreciated that in other embodiments, the number of upper roller sets 26 and/or the number of lower roller sets 28 may be greater or less than four. Further, the number of upper roller sets 26 may be distinct from the number of lower roller sets 28. In addition, FIG. 4 depicts an elevator roller insert 30 having three combination roller sets 32, but it will be appreciated that the elevator roller insert 30 may have more or less than three combination roller sets 32. As stated above, the rollers may have a maximum operating load and/or a maximum load rating, and similarly, the complete elevator roller insert 30 may also have a maximum operating load and/or a maximum load rating.

[0045] Now referring to FIG. 5, a cross section is shown comprising of a tubing 34 with an integral connection 36 being held in place by the upper rollers 4 in a generally abutting relationship. Due to the weight bearing rotational capabilities of the upper roller 4, the tubing 34 will be allowed to rotate rather freely within the elevator roller insert 30. The upper roller angle 10 is designed such that it will closely match the angle of the integral connection 36. The lower rollers 16 will then hold the tubing 34 centrally within the elevator roller insert 30 and, in the same manner as the upper rollers 4, would allow the tubular 34 to rotate rather freely. Also the upper 26 and lower roller sets 28 (or combination roller sets 32 in some embodiments) are radially aligned in a manner that the minimum internal diameter 38 of the elevator roller insert 30 is less than the greatest outer diameter of the integral connection 36. The internal diameter 38 of the elevator roller insert 30 keeps the tubular 34 from slipping through the insert 30 and falling to the rig floor.

[0046] Now referring to FIG. 6, a cross section is shown comprising of tubing 40 with an internally threaded sleeve 42 being held in place by the upper rollers 4 in a generally abutting relationship. Due to the weight bearing rotational capabilities of the upper roller 4, the tubing 40 will be allowed to rotate rather freely within the elevator roller insert 30. The lower rollers 16 will then hold the tubing 40 centrally within the elevator roller insert 30 and, in the same manner as the upper rollers 4, would allow the tubular 40 to rotate rather freely. Also the upper 26 and lower 28 roller sets (or combination roller sets 32 in some embodiments) are radially aligned in a manner that the minimum internal diameter 38 of the elevator roller insert 30 is less than the greatest outer diameter of the sleeve 42. The internal diameter 38 of the elevator roller insert 30 keeps the tubular 40 from slipping through the elevator roller insert 30 and falling to the rig floor.

[0047] And now referring to FIGS. 7a and 7b, an elevator roller insert 30 is shown within a single joint elevator 44 in the closed and opened position respectively. The elevator roller insert 30 is generally segmented to allow the elevator be opened, to accept the tubular, and closed, to contain the tubular within the elevator.

[0048] The invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed.

[0049] The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B, and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0050] Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification, drawings, and claims are to be understood as being modified in all instances by the term “about.”

[0051] The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

[0052] The use of “including,” “comprising,” or “having,” and variations thereof, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

[0053] It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. §112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts, and the equivalents thereof, shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

[0054] The foregoing description of the invention has been presented for illustration and description purposes. However, the description is not intended to limit the invention to only the forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.

[0055] Consequently, variations and modifications commensurate with the above teachings and skill and knowledge of the relevant art are within the scope of the invention. The embodiments described herein above are further intended to explain best modes of practicing the invention and to enable others skilled in the art to utilize the invention in such a manner, or include other embodiments with various modifications as required by the particular application(s) or use(s) of the invention. Thus, it is intended that the claims be construed to include alternative embodiments to the extent permitted by the prior art.