Actuation systems and related wrench tools and methods for making up and breaking out tubular connections

Abstract

Implementations described herein relate to actuation systems, wrench tools, and methods for making up and breaking out tubular connections. An actuation system for iron roughnecks includes an actuation assembly. The actuation assembly includes a carriage including a set of carriage rails, and a support frame. The support frame includes a set of support rails. The actuation system includes one or more actuators configured to extend and retract the carriage along a first direction. At least one of the one or more actuators is coupled between a carriage flange of the carriage and a support flange of the support frame.

1 . An actuation system for iron roughnecks, comprising:
 an actuation assembly comprising:
 a carriage comprising a set of carriage rails, 
 a support frame, the support frame comprising a set of support rails, and 
 one or more actuators configured to extend and retract the carriage along a first direction, at least one of the one or more actuators coupled between a carriage flange of the carriage and a support flange of the support frame. 
   
     
     
         2 . The actuation system of  claim 1 , wherein one of the carriage or the support frame is nested within the other of the carriage or the support frame. 
     
     
         3 . The actuation system of  claim 1 , wherein the set of support rails are aligned with the set of carriage rails, the set of carriage rails are spaced from each other and comprise carriage channels. 
     
     
         4 . The actuation system of  claim 3 , wherein the set of support rails comprise support channels, and the set of support rails are positioned inwardly or outwardly of the set of carriage rails. 
     
     
         5 . The actuation system of  claim 4 , wherein the carriage further comprises a carriage frame movable relative to the set of carriage rails, and the actuation assembly further comprises a plurality of rollers coupling the set of carriage rails to the set of support rails, and the plurality of rollers comprise:
 one or more carriage rollers respectively comprising a shaft section extending into an ear of the carriage frame and a head section configured to roll within one of the carriage channels; and   one or more support rollers respectively comprising a shaft section extending into one of the carriage rails and a head section configured to roll within one of the support channels.   
     
     
         6 . The actuation system of  claim 1 , and the actuation system further comprises:
 a second actuation assembly comprising:
 a second carriage comprising a set of second carriage rails, the set of second carriage rails spaced from each other, 
 a second support frame coupled to the carriage, the second support frame comprising a set of second support rails positioned inwardly or outwardly of the set of second carriage rails, 
 one or more second actuators configured to extend and retract the second carriage along a second direction that is oriented at an angle relative to the first direction, at least one of the one or more second actuators coupled between a carriage flange of the second carriage and a carriage platform of the carriage frame. 
   
     
     
         7 . The actuation system of  claim 6 , wherein the actuation assembly further comprises a plurality of rollers coupling the set of carriage rails to the set of support rails, the second actuation assembly further comprises a plurality of second rollers coupling the set of second carriage rails to the set of second support rails, and the plurality of second rollers respectively comprise a shaft section extending into one of the second carriage rails and a head section configured to roll within one of second support channels of the set of second carriage rails. 
     
     
         8 . The actuation system of  claim 6 , wherein the support frame is positioned at least partially around the carriage, and the second support frame is positioned at least partially around the second carriage. 
     
     
         9 . The actuation system of  claim 6 , wherein the direction is a horizontal direction and the second direction is a vertical direction. 
     
     
         10 . The actuation system of  claim 6 , wherein the second support frame is fixedly coupled to the carriage such that the second support frame and the second carriage are movable with the carriage along the first direction, and the second carriage is movable relative to the carriage along the second direction. 
     
     
         11 . The actuation system of  claim 1 , further comprising a slew bearing coupled to the actuation assembly and operable to rotate the actuation assembly. 
     
     
         12 . The actuation system of  claim 11 , wherein an extension range of the carriage relative to the slew bearing is adjustable. 
     
     
         13 . The actuation system of  claim 11 , further comprising:
 a rotational sensor operable to measure an angle of the slew bearing; and   one or more first position sensors operable to measure a horizontal position of the carriage along the first direction.   
     
     
         14 . The actuation system of  claim 13 , further comprising:
 a controller comprising instructions stored in a memory that, when executed by a processor, cause a plurality of operations to be conducted, the plurality of operations comprising:
 measuring the angle of the slew bearing using the rotational sensor; 
 measuring the horizontal position using the one or more first position sensors; and 
 comparing the angle and the horizontal position to a target position that corresponds to a rig floor position. 
   
     
     
         15 . The actuation system of  claim 14 , wherein the plurality of operations further comprise:
 powering the slew bearing to position the carriage at the angle; and   powering the one or more actuators to position the carriage at the horizontal position.   
     
     
         16 . The actuation system of  claim 1 , wherein the carriage further comprises a set of carriage rails and a carriage frame movable relative to the set of carriage rails, and the actuation system further comprises a linkage system coupled between the carriage and the support frame. 
     
     
         17 . The actuation system of  claim 16 , wherein the linkage system comprises:
 a first chain wound about a first gear coupled to a crossbar between the set of carriage rails and a second gear coupled to a connector bar between the carriage rails, the first chain comprising a first travel block coupled to the support frame; and   a second chain wound about a third gear coupled to the crossbar between the set of carriage rails and a fourth gear coupled to the connector bar between the carriage rails, the second chain comprising a second travel block coupled to the support frame.   
     
     
         18 . A wrench tool for making up and breaking out tubular connections on an oil and gas rig, the wrench tool comprising:
 an actuation assembly comprising:
 a carriage, 
 a support frame, and 
 one or more actuators configured to extend and retract the carriage along a first direction relative to the support frame; 
   a second actuation assembly comprising:
 a second carriage, 
 a second support frame coupled to the carriage, 
 one or more second actuators configured to extend and retract the second carriage along a second direction that is oriented at an angle relative to the first direction; 
   a spinner section comprising a plurality of spinner rollers, the spinner section coupled to the second carriage; and   a power tong section coupled to and suspended from the spinner section, the power tong section comprising a plurality of grippers and a plurality of tong actuators configured to pivot at least part of the power tong section.   
     
     
         19 . The wrench tool of  claim 18 , wherein the carriage is aligned under the spinner section and the power tong section. 
     
     
         20 . A method of making up or breaking out a tubular connection, the method comprising:
 extending a carriage linearly along a horizontal direction to linearly move a spinner section and a power tong section of a wrench tool, the extending of the carriage comprising:
 actuating one or more actuators coupled to the carriage to move the carriage relative to a support frame positioned at least partially around the carriage; 
   extending a second carriage linearly along a vertical direction to linearly move the spinner section and the power tong section of the wrench tool, the extending of the second carriage comprising:
 actuating one or more second actuators coupled between the second carriage and the carriage; 
   positioning a first tubular and a second tubular in a first opening of the power tong section and a second opening of the spinner section;   spinning the second tubular relative to the first tubular using a plurality of spinner rollers of the spinner section; and   pivoting at least part of the power tong section to torque the second tubular relative to the first tubular.   
     
     
         21 . The method of  claim 20 , wherein:
 the extending of the second carriage occurs prior to the extending of the carriage;   the extending of the second carriage vertically clears the spinner section and the power tong section above a piece of equipment disposed along a rig floor; and   the extending of the carriage extends the spinner section and the power tong section horizontally past the piece of equipment and toward a well center opening formed in the rig floor.