Method and apparatus for forming tubular connections

A replacement cage assembly to modify a power tong to grip and rotate a tubular, comprising:

• a rotary gear insert receivable within an interior of a rotary gear rotatably coupled to the power tong, the rotary gear insert comprising:
• an interior;
• a radially outwardly disposed surface with a periphery exceeding about 180 degrees and receivable within the interior of the rotary gear;
• and
• cam surface to engage and cam at least one gripping jaw radially inwardly to grip and rotate a tubular introduced into the interior of the rotary gear insert and positioned adjacent the at least one gripping jaw;
• wherein the interior of the interior of the rotary gear has a profile generally complimentary to, and extending at least about 180 degrees about, the radially outwardly disposed surface of the rotary gear insert receivable therein to facilitate the transfer of a torque from the rotary gear to the rotary gear insert.

A method of using a power tong, having a rotary gear rotatable in a plane about an axis, to grip and rotate a first tubular, the method comprising the steps of:

• providing a rotary gear insert having a radially outwardly disposed surface with a periphery exceeding about 180 degrees about the axis and received within a generally complimentary interior of the rotary gear, the rotary gear insert further comprising an interior having a cam surface;
• movably securing at least one gripping jaw within the interior of the rotary gear insert adjacent to the cam surface;
• disposing the first tubular within the interior of the rotary gear insert and generally adjacent the gripping jaw;
• transferring a torque through the rotary gear to the rotary gear insert disposed within the interior of the rotary gear to rotate the rotary gear insert about the axis and through a first angular displacement to move the at least one gripping jaw into engagement with the first tubular;
• and
• continuing to transfer the torque to rotate the rotary gear insert about the axis to rotate the first tubular.

A method of modifying a power tong having a rotary gear having an interior to receive a rotary gear insert, the rotary gear being rotatable within a plane about an axis, comprising the steps of:

• providing a rotary gear insert, having an interior and a radially outwardly disposed surface with a periphery exceeding about 180 degrees and a profile complimentary to a profile of the interior of the rotary gear;
• pivotally disposing a plurality of gripping jaws within the interior of the rotary gear insert to be cammed radially inwardly by angular displacement of the rotary gear insert about the axis;
• and
• moving the rotary gear insert along the axis to install the rotary gear insert within the complimentary interior profile of the rotary gear.

A replacement cage assembly to modify a power tong having a rotary gear rotatable within a plane about an axis, the replacement cage assembly comprising:

• a rotary gear insert, comprising an interior having a radially inwardly disposed cam surface and a radially outwardly disposed surface with a periphery exceeding about 180 degrees about the axis;
• and
• a plurality of gripping jaws pivotally disposed within the interior of the rotary gear insert;
• wherein the replacement cage plate assembly is installable in the power tong by moving the rotary gear insert along the axis to install the rotary gear insert within a generally complimentary profile of the interior of the rotary gear;
• and
• wherein a torque may be transferred through the rotary gear to the rotary gear insert at an interface spanning at least about 180 degrees and disposed between the interior of the rotary gear and the radially outwardly disposed surface of the rotary gear insert.