Expandable drum assembly for deploying coiled pipe and method of using same

1. A drum assembly, comprising:

a support bar having a first end and a second end;

a first plurality of expandable spokes extending away from the first end of the support bar, wherein a distal end of each of the first plurality of expandable spokes is movable between a retracted position and an extended position;

a second plurality of expandable spokes extending away from the second end of the support bar, wherein a distal end of each of the second plurality of expandable spokes is movable between a retracted position and an extended position;

a plurality of drum segments each mounted to the distal end of one of the first plurality of expandable spokes and the distal end of one of the second plurality of expandable spokes, wherein each of the plurality of drum segments extends parallel to the support bar;

a first support bracket disposed about the support bar proximate the first end of the support bar and configured to slide over an outer surface of the support bar along a first longitudinal section of the support bar;

a second support bracket disposed about the support bar proximate the second end of the support bar and configured to slide over the outer surface of the support bar along a second longitudinal section of the support bar;

a primary mechanical actuator coupled to the first support bracket and the second support bracket, wherein the primary mechanical actuator is capable of moving at least one of the first support bracket, the second support bracket, or both;

a first plurality of secondary mechanical actuators each extending between the first support bracket and one of the first plurality of expandable spokes or one of the plurality of drum segments, wherein the first plurality of secondary mechanical actuators are capable of moving the location of the first plurality of expandable spokes between the retracted and extended positions;

a second plurality of secondary mechanical actuators each extending between the second support bracket and one of the second plurality of expandable spokes or one of the plurality of drum segments, wherein the second plurality of secondary mechanical actuators is capable of moving the location of the second plurality of expandable spokes between the retracted and extended positions, and wherein the primary and secondary mechanical actuators comprise hydraulic cylinders; and

a flow distributor configured to distribute flow of hydraulic fluid to the hydraulic cylinders.

2. The drum assembly of claim 1 , wherein each of the first and second pluralities of expandable spokes comprises:

a hollow tube connected to the support bar; and

a rigid member telescopically slidably disposed in the hollow tube.

3. The drum assembly of claim 1 , comprising a first hub disposed at the first end of the support bar and a second hub disposed at the second end of the support bar, wherein the first hub comprises a first hub shaft and the second hub comprises a second hub shaft.

4. The drum assembly of claim 1 , comprising a first plurality of extension arms disposed at the first end of the support bar and a second plurality of extension arms disposed at the second end of the support bar, wherein the first and second pluralities of extension arms are movable into an extended position configured to contain flexible pipe disposed on the drum assembly between the first and second pluralities of extension arms.

5. The drum assembly of claim 1 , comprising a first containment flange disposed at the first end of the support bar and a second containment flange disposed at the second end of the support bar, wherein the first and second containment flanges are configured to contain flexible pipe disposed on the drum assembly between the first and second containment flanges.

6. The drum assembly of claim 5 , wherein the first and second containment flanges are removably coupled to the support bar.

7. The drum assembly of claim 5 , comprising a brake configured to engage at least one of the first and second containment flanges, wherein the brake is configured to slow or stop rotation of at least one of the first and second containment flanges when the brake is activated.

8. The drum assembly of claim 5 , wherein the first containment flange is disposed closer to the first end of the support bar than the first plurality of expandable spokes, or the second containment flange is disposed closer to the second end of the support bar than the plurality of second plurality of expandable spokes, or both.

9. The drum assembly of claim 1 , comprising at least two fork channels extending axially or radially along the support bar.

10. The drum assembly of claim 1 , wherein the flow distributor equalizes hydraulic fluid flow to the hydraulic cylinders such that the plurality of drum segments are moved evenly as the first and second pluralities of expandable spokes are moved between the retracted position and the extended position.

11. The drum assembly of claim 1 , wherein the flow distributor is configured to sequence movement of the plurality of drum segments.

12. A method of engaging a drum assembly with a coil of flexible pipe, comprising:

disposing the drum assembly within an interior region of the coil of flexible pipe, the drum assembly comprising:

a support bar having a first end and a second end;

a first plurality of expandable spokes extending away from the first end of the support bar, wherein a distal end of each of the first plurality of expandable spokes is movable between a retracted position and an extended position;

a second plurality of expandable spokes extending away from the second end of the support bar, wherein a distal end of each of the second plurality of expandable spokes is movable between a retracted position and an extended position;

a plurality of drum segments each mounted to the distal end of one of the first plurality of expandable spokes and the distal end of one of the second plurality of expandable spokes, wherein each of the plurality of drum segments extends parallel to the support bar;

a first support bracket disposed about the support bar proximate the first end of the support bar and configured to slide over an outer surface of the support bar along a first longitudinal section of the support bar;

a second support bracket disposed about the support bar proximate the second end of the support bar and configured to slide over the outer surface of the support bar along a second longitudinal section of the support bar;

a primary mechanical actuator coupled to the first support bracket and the second support bracket, wherein the primary mechanical actuator is capable of moving at least one of the first support bracket, the second support bracket, or both;

a first plurality of secondary mechanical actuators each extending between the first support bracket and one of the first plurality of expandable spokes or one of the plurality of drum segments, wherein the first plurality of secondary mechanical actuators are capable of moving the location of the first plurality of expandable spokes between the retracted and extended positions;

a second plurality of secondary mechanical actuators each extending between the second support bracket and one of the second plurality of expandable spokes or one of the plurality of drum segments, wherein the second plurality of secondary mechanical actuators is capable of moving the location of the second plurality of expandable spokes between the retracted and extended positions, and wherein the primary and secondary mechanical actuators comprise hydraulic cylinders; and

a flow distributor configured to distribute flow of hydraulic fluid to the hydraulic cylinders; and

moving the first plurality of expandable spokes and the second plurality of expandable spokes from the retracted position to the extended position using at least one of the primary mechanical actuator, the first plurality of secondary mechanical actuators, the second plurality of secondary mechanical actuators, or any combination thereof; and

contacting the coil of flexible pipe with at least two of the plurality of drum segments such that the drum assembly is secured within the interior region of the coil of flexible pipe.

13. The method of claim 12 , wherein each of the first and second pluralities of expandable spokes comprise a hollow tube connected to the support bar and a rigid member telescopically slidably disposed in the hollow tube.

14. The method of claim 12 , comprising distributing flow of hydraulic fluid to one or more of the primary or secondary mechanical actuators via a flow distributor to control movement of the first and second pluralities of expandable spokes.

15. The method of claim 12 , comprising lifting the drum assembly via a first hub disposed at the first end of the support bar and a second hub disposed at the second end of the support bar.

16. The method of claim 12 , comprising containing flexible pipe disposed on the drum assembly via a first plurality of extension arms disposed at the first end of the support bar and a second plurality of extension arms disposed at the second end of the support bar, or via a first containment flange disposed at the first end of the support bar and a second containment flange disposed at the second end of the support bar.

17. The method of claim 16 , comprising driving rotation of the first and second containment flanges via rotation of the support bar and removably coupling the first and second containment flanges to the support bar.

18. The method of claim 16 , comprising slowing or stopping rotation of the first and second containment flanges via a brake engaged with the first and second containment flanges.

19. The method of claim 12 , wherein the flow distributor equalizes hydraulic fluid flow to the hydraulic cylinders such that the plurality of drum segments are moved evenly as the first and second pluralities of expandable spokes are moved between the retracted position and the extended position.

20. The method of claim 12 , wherein the flow distributor is configured to sequence movement of the plurality of drum segments.