Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD FOR MODIFIED
HORIZONTAL DIRECTIONAL DRILLING ASSEMBLY
FIELD OF THE INVENTION
This invention relates generally to assemblies and methods for subsurface
drilling, and
particularly to assemblies and methods for horizontal directional and vertical
subsurface drilling.
BACKGROUND AND DESCRIPTION OF THE PRIOR ART
It is known to use a vertical drilling rig in oil, gas and coal bed methane
well drilling.
Conventional vertical dr-illing rigs use heavy drill pipe or drill collars in
order to exert downward
force on the drill bit as it enters the earth's surface and begins the well
bore. As the drill bit of
the conventional vertical drilling rig drills deeper below the earth's
surface, it is sometimes
necessary to apply force in the opposite direction of the drilling direction
(pull-back force) in
order to prevent placing too much weight on the drill bit and causing damage
to or failure of the
drill bit.
It is also known to drill oil, gas and methane wells in a vertical direction
initially and then
deviate or turn the well bore in increments toward a horizontal direction as
the drill bit reaches
the target formation. The bore hole is then continued in the horizontal
direction for a distance.
This method exposes a greater volume of the oil, gas and methane producing
formation to the
well bore and produces a higher and longer producing well. In order to covert
a vertical drilling
rig to accomplish the combination vertical-horizontal drilling, it is
necessary to retrofit the
vertical drilling rig with a top drive adapted to fit into the derrick
structure and provide rotational
force to the drill pipe, rather than just a rotary table and Kelly bar.
Conventionally, a rotary table
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is fixed to the drill rig floor or base such that it does not move up and down
with the drill pipe.
A heavy fluted round piece of drill pipe called a Kelly bar slides through the
rotary table opening
and connects to the drill pipe or casing. The keys that engage with the Kelly
bar impart the
torque to the drill pipe string and permit the Kelly bar to raise and lower
through the rotary table
opening. The top drive also provides thrust and pull-back forces which are
needed while drilling
in the horizontal direction. However, the distances of the horizontal runs
produced by
conventional devices and methods are limited by the capability of the top
drive to apply tlu-ust
and pull-back forces to the drill pipe. The diameters of the horizontal runs
are also limited by the
ability to apply thrust and pull-back forces to the drill pipe.
It is also known to use a variation of the vertical-horizontal drilling method
described above
which is called slant drilling. In slant drilling, a vertical oil, gas,
methane drilling rig is
retrofitted such that the derrick is disposed at an angle, e.g., 45 to 60
from horizontal. A top
drive applies the rotational, thrust and pull-back forces to the drill pipe.
It is further known to
use drilling rigs commonly known as super singles for subsurface drilling
applications relating to
oil, gas,and methane. Super single drilling rigs utilize longer Range III
drill pipe lengths which
are 45 feet in length. Super single drilling rigs, therefore, reduce the
number of tool joint
connections that are required to be made during a subsurface drilling
operation. Consequently,
the drilling process can be completed more quickly. Super singles utilize a
top drive to rotate the
drill pipe, to provide the thrust needed for the drill bit to cut and to
control the steering of the
cutting assembly. Conventional super singles include top drive units having
limited thrust
capacity and limited rotary torque capacity. Thus, the horizontal distances
and bore hole
diameter that may be achieved using a super single are limited.
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Still further, conventional drilling rigs include power units that are
separate from the drilling
apparatus and therefore require multiple truckloads to transport the drill
rig. Conventional oil,
gas and methane drilling assemblies are not anchored to the ground so as to
increase
performance specifications. Instead, conventional drilling rigs use their own
weight to control
the machine performance specifications. As a result, convention drilling
machines are very
heavy and require multiple truckloads to transport. Conventional oil, gas and
methane drilling
rigs also use heavy weighted drill collars in the drill pipe string in order
to provide the thrust
force to the drill pipe and a winch and cable system to provide the pull-back
force. Weighted
drill collars, however, are not effective in the horizontal direction. Some
conventional oil, gas
and methane drilling rigs use hydraulic cylinders to provide the tnist and
pull-back forces.
Further, conventional oil, gas and methane machines frequently damage the
threaded end of a
drill string section when the top drive or rotary table engages the threaded
end of the drill string
section.
Still further, conventional drilling assemblies do not include a roller drill
pipe guide bushing
assembly adapted to reduce the wear and damage to the drill pipe string.
Conventional drilling
assemblies do not include automated drill pipe slips adapted to reduce the
amount of time
required to perform make-up and break-out operations on the drill pipe andlor
casing tool joints.
Conventional drilling assemblies do not include pipe handling arms adapted to
be pinned to the
sub-stntcture for easy removal during transport. Conventional drilling
assemblies do not include
a positive rack and pinion carriage (top drive) system which is adapted to
provide thrust and pull-
back forces to the drill pipe string and eliminate the need for cables,
winches, hydraulic
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cylinders, chain systems and the like to provide such forces. Conventional
drilling assemblies
also do not include a slip spindle sub asseinbly which is incorporated into
the top drive system
and adapted to reduce damage and wear to the drill pipe or casing thread.
It would be desirable therefore, if a drilling assembly could be provided that
would produce an
increased capacity for drill pipe rotational, thrust and pull-back forces. It
would also be desirable
if a drilling assembly could be provided that would produce longer well bores
and well bores
having a greater diameter than those produced by conventional drilling
assemblies. It would also
be desirable if a drilling assembly could be provided that would be capable of
entering the earth
and drilling a well bore at an angle steeper than conventional horizontal
directional drill
assemblies. It would also be desirable if a drilling assembly could be
provided that would be
capable of entering the earth and drilling a well bore at an angle closer to
horizontal than
conventional vertical drill assemblies. It would also be desirable if a
drilling assembly could be
provided that would eliminate the need for heavy drill pipe or drill collars
to exert downward
force on the drill bit. It would also be desirable if a drilling assembly
could be provided that
would .be more easily transported. It would also be desirable if a drilling
assembly could be
provided that is adapted to be anchored to the ground so as to increase
performance
specifications. It would also be desirable if a drilling assembly could be
provided that would
eliminate the need for cables, winches, hydraulic cylinders, chain systems and
the like to provide
rotational, thnist and pull-back forces. It would be desirable if a drilling
assembly could be
provided that would reduce the damage and wear to the threaded end of a drill
string, section
when the top drive or rotary table engages the threaded end of the drill
string section. It would
be desirable if a drilling assembly could be provided that would reduce the
amount of time
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required to perform make-up and break-out operations on the drill pipe and/or
casing tool joints.
It would be desirable if a drilling assembly could be provided that includes
pipe handling arms
adapted to be pinned to the sub-structure for easy removal during transport.
It would be
desirable if a drilling assembly could be provided that is adapted to perform
vertical and
horizontal drilling applications with a tube-in-tube drill string. It would
also be desirable if a
drilling assembly could be provided that would be adapted to continue
operations in the event of
a power unit failure.
ADVANTAGES OF THE INVENTION
Among the advantages of the invention is to provide a drilling assembly that
produces an
increased capacity for drill pipe rotational, thrust and pull-back forces. It
is also an advantage of
the invention to provide a drilling assembly that is capable of producing
longer well bores and
well bores having a greater diameter than those produced by conventional
drilling assemblies. It
another advantage of the invention to provide a drilling assembly that is
capable of entering the
earth and drilling a well bore at an angle steeper than conventional
liorizontal directional drill
assemblies. It is still another advantage of the invention to provide a
drilling assembly that is
capable of entering the earth and drilling a well bore at an angle closer to
horizontal than
conventional vertical drill assemblies. It is yet another advantage of the
invention to provide a
drilling assembly that eliminates the need for heavy drill pipe or drill
collars to exert downward
force on the drill bit. It is a further advantage of the invention to provide
a drilling assembly that
is more easily transported. It is a still further advantage of the invention
to provide a drilling
assembly that may be anchored to the ground so as to increase performance
specifications. It is
also an advantage of the invention to provide a drilling assembly that
eliminates the need for
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cables, winches, hydraulic cylinders, chain systems and the like to provide
rotational, thrust and
pull-back forces. It is also an advantage of the invention to provide a
drilling assembly that
reduces the damage and wear to the threaded end of a drill string section when
the top drive or
rotary table engages the threaded end of the drill string section. It another
advantage of the
invention to provide a drilling assembly that reduces the amount of time
required to perform
make-up and break-out operations on the drill pipe and/or casing tool joints.
It is a further
advantage of the invention to provide a drilling assembly that includes pipe
handling arms
adapted to be pinned to the sub-structure for easy removal during transport.
It is a still further
advantage of the invention to provide a drilling assembly that is adapted to
perform vertical and
horizontal drilling applications with a tube-in-tube drill pipe or a tube-in-
tube drill pipe string. It
is another advantage of the invention to provide a drilling assembly that may
be continuously
operated in the event of a power unit failure.
Additional advantages of this invention will become apparent from an
examination of the
drawings and the ensuing description.
EXPLANATION OF TECHNICAL TERMS
As used herein, the ternl "drilling a drill pipe into a drilling surface"
includes drilling a bore
hole into which a drill pipe or a drill pipe string is pulled. The term
"drilling a drill pipe into a
drilling surface" also includes pulling the drill pipe or the drill pipe
string out of the bore hole.
As used herein, the term "drilling surface" includes the Earth's subsurface
strata and any other
medium into which a bore hole may be drilled.
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As used herein, the term "hydraulic actuator" includes hydraulic cylinders,
hydraulic rotary
actuators, pneumatic cylinders and any other device or system in which
pressurized fluid is used
to impart a mechanical force.
As used herein, the term "tube-in-tube" refers to a type of drill pipe or
drill pipe string
characteiized by an outer drill pipe wall and a substantially axially
positioned inner drill pipe
wall that is substantially surrounded by the outer drill pipe wall.
SUMMARY OF THE INVENTION
The apparatus claimed herein comprises a modified horizontal directional
drilling assembly for
drilling pipe into a drilling surface. The drilling assembly comprises a power
unit for supplying
power to the assembly, a thrust frame adapted to be moved between a position
substantially
parallel to the drilling surface and a position substantially perpendicular to
the drilling surface
and a means for moving the thrust frame. The drilling assembly further
comprises a rotary and
carriage assembly mounted on the thrust frame. The rotary and carriage
assembly is adapted to
apply rotational, thrust and pull-back forces to the drill pipe. The drilling
assembly is adapted to
drill pipe into the drilling surface at any angle relative to the drilling
surface between
substantially parallel to the drilling surface and substantially perpendicular
to the drilling surface.
The method for drilling pipe into a drilling surface claimed herein comprises
providing a
modified horizontal directional drilling assenibly. The drilling assembly
comprises a power unit
for supplying power to the assembly, a thrust frame adapted to be moved
between a position
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substantially parallel to the drilling surface and a position substantially
perpendicular to the
drilling surface, a means for moving the thrust frame, and a rotary and
carriage assembly
mounted on the thrust frame. The rotary and carriage assembly is adapted to
apply rotational,
thrust and pull-back forces to the drill pipe. The drilling assembly is
adapted to drill pipe into
the drilling surface at any angle relative to the drilling surface between
substantially parallel to
the drilling surface and substantially perpendicular to the drilling surface.
The method further
comprises placing a drill pipe onto the drilling assembly,' moving the thrust
frame to a desired
drilling angle, moving the rotary and carriage assembly into direct contact
with the drill pipe,
applying rotational, thrust and pull-back forces to the drill pipe, and
drilling the pipe into the
drilling surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The presently preferred embodiments of the invention are illustrated in the
accompanying
drawings, in which like reference numerals represent like parts throughout,
and in which:
Figure 1 is a side view of a preferred embodiment of the modified horizontal
directional drilling
assembly in accordance with the present invention illustrating the drilling
assembly in a retracted
transport position approaching a drilling site.
Figure 2 is a side view of the preferred modified horizontal directional
drilling assembly shown
in Figure 1 illustrating the drilling assembly in a retracted transport
position on a preferred sub-
structure.
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Figure 3 is a side view of the preferred modified horizontal directional
drilling assembly shown
in Figures 1-2 illustrating the drilling assembly in a vertical subsurface
drilling position with the
drill pipe in a horizontal stored position.
Figure 4 is a top view of the preferred modified horizontal directional
drilling assembly shown in
Figure 3.
Figure 5 is a side view of the preferred modified horizontal directional
drilling assembly shown
in Figures 1-4 illustrating the drilling assembly in a vertical subsurface
drilling position with the
drill pipe in a vertical drilling position and illustrating a preferred
anchoring system.
Figure 6 is a side view of the preferred embodiment of the modified horizontal
directional
drilling assembly shown in Figures 1-5 illustrating the drilling assembly in a
45 angle slant
subsurface drilling position with the drill pipe in a horizontal stored
position.
Figure 7 is a side view of the preferred embodiment of the modified horizontal
directional
drilling assembly shown in Figures 1-6 illustrating the drilling assembly and
the drill pipe in a
45 angle slant subsurface drilling position.
Figure 8 is a side view of the rotary and carriage assembly of the preferred
embodiment of the
modified horizontal directional drilling assembly sliown in Figures 1-7.
Figure 9 is a top view of the preferred rotary and carriage assembly shown in
Figures 1-8.
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Figure 10 is a partial sectional side view of the telescoping slip spindle sub
assembly of the
preferred embodiment of the modified horizontal directional drilling assembly
shown in Figures
1-9 illustrating the slip spindle sub assembly output spindle in a retracted
conditiom.
Figure 11 is a partial sectional side view of the telescoping slip spindle sub
assembly of the
preferred embodiment of the modified horizontal directional drilling assembly
shown in Figures
1-10 illustrating the slip spindle sub assembly output spindle in an extended
condition.
Figure 12 is an end view of the telescoping slip spindle sub assembly of the
preferred
embodiment of the modified horizontal directional drilling assembly shown in
Figures 1-11.
Figure 13 is a side view of a first alternative embodiment of the modified
horizontal directional
drilling assembly of the present invention illustrating the fixed pivot and
the wide strut system.
Figure 14 is a top view of the first alternative embodiment of the modified
horizontal directional
drilling assembly illustrated in Figure 13.
Figure 15 is a top view of an alternative embodiment of the rotary and
carriage assembly of the
preferred modified 1lorizontal directional drilling assembly of the present
invention.
Figure 15A is an enlarged view of the lower portion of the preferred rotary
and carriage
assembly illustrated in Figure 15.
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Figure 16 is a side view of the alternative embodiment of the rotary and
carriage assembly
illustrated in Figures 15 and 15A.
DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
Refen-ing now to the drawings, the preferred embodiment of the apparatus and
method for the
modified horizontal directional drilling assembly of the invention is
illustrated in Figures 1
through 12. More particularly, as shown in Figures 1 through 12, the preferred
modified
horizontal directional drilling assembly ("modified HDD assembly") is
designated generally by
reference numera130. The preferred modified HDD assembly 30 is adapted for use
in both
horizontal directional drilling applications and vertical subsurface drilling
applications such as
oil, gas and methane subsurface drilling.
As shown in Figure 1, the preferred modified HDD assembly 30 preferably
includes a pair of
power units 32 and 34 (not shown). The preferred power units are diesel
engines, but it is
contemplated within the scope of the invention that any suitable power source
such as electric
motors, diesel engines and generators and the like may be used. A plurality of
power units are
provided so that drilling operations can continue in the event of the failure
of less than all of the
power units. More particularly, the preferred HDD assembly 30 comprises two
independent
power units so that if one of the power units requires repair or maintenance,
or if the hydraulic
system connected to one of the power units requires repair or maintenance, the
assembly can still
be operated at ftill capacity (at half speed) by the other power unit and the
drilling operation can
continue uninterrupted (run-on-one-technology ("ROOT")). Consequently, the
risk of bore hole
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wall collapse is minimized. The power units are preferably attached to the
modified HDD
assembly such that they can be transported with the assembly as a single unit.
It is contemplated
within the scope of the invention, however, that the power units may be
removably attached to
and transported separate from the other components of the drilling assembly.
Still referring to Figure 1, the preferred modified HDD assembly 30 also
includes rotary and
carriage assembly 40. The preferred rotary and carriage assembly 40 is adapted
to move along
thnist frame 42 and provide thrust force, pull-back force and rotational
torque to a drill pipe or
casing. The preferred rotary and carriage assembly is a positive rack and
pinion carriage system
which eliminates the need for cable, winches, hydraulic cylinders, chain
systems and the like.
The preferred modified HDD assembly further includes breakout wrench assembly
50 and roller-
style anti-friction drill pipe guide bushing assembly 60. The preferred
breakout wrench
assembly 50 is adapted to make-up and break-out the drill pipe tool
connections. The preferred
bushing assembly 60 is adapted to reduce wear on the drill pipe string.
In addition, the preferred HDD assembly 30 includes a pair of pivoting hinges
70 (see also
Figure 4) which are adapted to permit thrust frame 42 to be pivotally moved
between a position
approximately parallel to the drilling surface (as sliown in Figure 1) and a
position approximately
perpendicular to the drilling surface (as shown in Figure 3). The preferred
pivoting hinge 70 is a
double hinge arrangement having two pivot points. It is contemplated within
the scope of the
invention, however, that the pivoting hinge may have less than or more than
two pivot points. It
is further contemplated witlun the scope of the invention that less than or
more than two pivoting
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hinges may be used to move thrust frame between a position approximately
parallel to the
drilling surface and a position approximately perpendicular to the drilling
surface.
Preferably, the rotary and camage assembly 40 and thrust frame 42 are moved
between an
approximately horizontal position and an approximately vertical position by
frame hydraulic
cylinders 44 (see also Figure 4). It is contemplated within the scope of the
invention, however,
that any suitable device or assembly may be used to pivotally move the rotary
and carriage
assembly and the thrust frame between an approximately horizontal position and
an
approximately vertical position such as a motor and chain assembly, a motor
and cable assembly,
a motor and gear assembly and the like. It is further contemplated that less
than or more than
two hydraulic cylinders may be provided to move the rotary and carriage
assembly and the thrust
frame between an approximately horizontal position and an approximately
vertical position. It is
still further contemplated that the rotary and carriage assembly and the
thrust frame may be
moved beyond an approximately vertical position through an approximately 90
arc.
Still referring to Figure 1, the prefelTed modified HDD assembly 30 also
includes sub-structure
80 which is adapted to raise the assembly to a sufficient height so as to
clear a blow-out
preventer (BOP). In addition, sub-structure 80 is adapted to anchor the
assembly to the ground
(as shown in Figure 5) such that thrust forces in excess of the weight of the
assembly and sub-
structure may be applied to the drill pipe or casing. The sub-structure
illustrated by Figure 1 is
shown in a disassembled condition for transport. The preferred modified HDD
assembly 30
further includes remote operated drill pipe or casing slip assembly 85. The
preferred slip
assembly 85 is adapted to prevent a drill pipe from dropping down into the
drill bore. In
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addition, the preferred slip assembly 85 is adapted to reduce the amount of
time required to
perform drill pipe and/or casing tool joint make-up and break-out operations.
Still fiirther, the
preferred slip assembly 85 functions as a safety feature by keeping personnel
away from the
moving drill pipe and casing.
Referring still to Figure 1, drill pipe and casing handler 90 is adapted to
pick up drill pipe 100 or
casing from an approximately horizontal position substantially parallel to the
drilling surface
(such as the position in wluch drill pipes or casings are stored in storage
racks). Further, the
preferred handler 90 is adapted to pivotally move drill pipe 100 or a casing
to an approximately
vertical position substantially perpendicular to the drilling surface for
vertical subsurface drilling
applications. Still further, the preferred handler 90 is adapted to pivotally
move drill pipe 100
beyond an approximately vertical position as shown in Figure 7. In addition,
the preferred
handler 90 is adapted to hold the drill pipe or casing in position until the
rotary and carriage
assembly is connected to the drill pipe or casing. The preferred handler 90 is
adapted to move
the drill pipe or casing into an infinite number of positions from an
approximately horizontal
stored position to an appropriate position for connection of the drill pipe or
casing with the rotary
and carriage assembly. The preferred handler 90 is removably connected to sub-
structure 80 by
one or more pin conriections.
Still referring to Figure 1, handler 90 and drill pipe 100 or a casing are
preferably moved from
the approximately horizontal stored position to an appropriate position for
connection of the drill
pipe or casing with the rotary and carriage unit by handler hydraulic cylinder
92. It is
contemplated within the scope of the invention, however, that any suitable
device or assembly
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may be used to pivotally move the drill pipe and casing handler between an
approximately
horizontal stored position and an appropriate position for connection of the
drill pipe or casing
with the rotary and carriage assembly such as a motor and chain assembly, a
motor and cable
assembly, a motor and gear assembly, a rotary actuator and the like. It is
further contemplated
that a plurality of hydraulic cylinders may be provided to move the drill pipe
and casing handler
between an approximately stored horizontal position and an appropriate
position for connection
of the drill pipe or casing with the rotary and carriage assembly. The
preferred drill pipe 100 is
shown in the stored horizontal position. The preferred handler 90 is shown in
a condition ready
for loading and transport.
Still referring to Figure 1, the preferred modified HDD assembly 30 further
includes a plurality
of leveling jacks 110. Leveling jacks 110 are preferably mounted to the
assembly and adapted to
level the assembly. In addition, the preferred leveling jacks 110 provide
stability to modified
HDD assembly 30. Further, the preferred leveling jacks 110 are mounted to sub-
structure 80 in
order to provide additional anchoring forces to the assembly.
Referring now to Figure 2, a side view of preferred modified HDD assembly 30
is illustrated.
More particularly, Figure 2 illustrates preferred modified HDD assembly 30 in
a retracted
transpart position on preferred sub-structure 80. As shown in Figure 2,
preferred modified HDD
assembly 30 includes power unit 32 (power unit 34 not shown), rotary and
carriage assembly 40,
thrust frame 42, frame hydraulic cylinder 44, breakout wrench assembly 50,
bushing assembly
60, pivoting hinge 70, sub-stnicture 80, slip assembly 85, drill pipe and
casing handler 90,
handler hydraulic cylinder 92, drill pipe 100 and leveling jacks 110.
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Referring now to Figure 3, a side view of the preferred modified HDD assembly
30 is illustrated.
More particularly, Figure 3 shows the preferred modified HDD assembly 30 in
position for a
vertical subsurface drilling application. The preferred drill pipe 100 is
shown in a horizontal
stored position. As shown in Figure 3, preferred modified HDD assembly 30
includes power
unit 32 (power unit 34 not shown), rotary and carriage assembly 40, thrust
frame 42, frame
hydraulic cylinder 44, breakout wrench assembly 50, bushing assembly 60,
pivoting hinge 70,
sub-structure 80, slip assembly 85, drill pipe and casing handler 90, handler
hydraulic cylinder
92, drill pipe 100 and leveling jacks 110. Further, as shown in Figure 3,
rotary and carriage
assembly 40 and thrust frame 42 of preferred modified HDD assembly 30 are
adapted to be
pivotally rotated from a position approximately parallel to the drilling
surface (as shown in
Figures 1 and 2) to a position approximately perpendicular to the drilling
surface in order to
perform vertical subsurface drilling applications. Rotary and carriage
assembly 40 and thrust
frame 42 are preferably moved between an approximately horizontal position and
an
approximately vertical position by frame hydraulic cylinder 44.
Referring now to Figure 4, a top view of the preferred modified HDD assembly
30 is illustrated.
More particularly, Figure 4 illustrates preferred modified HDD assembly 30 in
the position
shown in Figure 3 with the preferred pivoting hinges 70 in a lowered position.
As shown in
Figure 4, modified HDD assembly 30 includes power unit 32, power unit 34,
rotary and carriage
assembly 40, thrust frame 42, frame hydraulic cylinders 44, pivoting hinges
70, sub-structure 80,
drill pipe and casing handler 90, drill pipe 100 and leveling jacks 110.
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Referring now to Figure 5, a side view of the preferred modified HDD assembly
30 is illustrated.
More particularly, Figure 5 illustrates preferred modified HDD assembly 30 in
a vertical
subsurface drilling application with drill pipe and casing handler 90 and
drill pipe 100 in a
vertical drilling position. Further, Figure 5 illustrates the preferred
anchoring system 115. As
shown in Figure 5, preferred modified HDD assembly 30 includes power unit 32
(power unit 34
not shown), rotary and carriage assembly 40, thrust frame 42, frame hydraulic
cylinder 44,
breakout wrench assembly 50, bushing assembly 60, pivoting hinge 70, sub-
structure 80, slip
assembly 85, drill pipe and casing handler 90, handler hydraulic cylinder 92,
drill pipe 100,
leveling jacks 110 and tipping plate anchors 120. Further, as shown in Figure
5, drill pipe and
casing handler 90 is adapted to releasable retain and pivotally move drill
pipe 100 from a
position approximately parallel to the drilling surface (as shown in Figures 1-
3) to a position
approximately perpendicular to the drilling surface. Preferably, drill pipe
and casing handler 90
is moved between a position approximately parallel to the drilling surface and
a position
approximately perpendicular to the drilling surface by handler hydraulic
cylinder 92.
Still referring to Figure 5, the preferred anchoring system 115 includes
tipping plate anchors 120
which are adapted to be driven into the ground to the required depth. Anchor
rod 122 extends
from the tipping plate anchors 120 to the ground surface. Anchor rod 122 may
be connected to
sub-structure 80 by anchor hydraulic cylinder 124. The preferred anchor
hydraulic cylinder 124
is adapted to be set into a socket into the frame of sub-stnicture 80 such
that the cylinder may be
pivoted for alignment with the anchor rod. The preferred anchor hydraulic
cylinder is also
adapted to tip the tipping plate anchor and maintain a pre-determined
hydraulic pressure such
that the desired anchor rod tensional load will be maintained during drilling
operations. In the
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alteinative, anchor rod 122 may be connected to sub-structure 80 using a split
tapered bushing
which is adapted to lock onto the anchor rod and be inserted into a tapered
housing connected to
the sub-structure. As the anchor loads are increased, the split tapered
bushing fits more tightly in
the tapered housing, thereby increasing the anchor rod grip force.
Referring now to Figure 6, a side view of the preferred modified HDD assembly
30 is illustrated.
More particularly, Figure 6 illustrates rotary and carriage assembly 40,
thrust frame 42, drill pipe
and casing breakout wrench assembly 50, drill pipe guide bushing assembly 60
and slip
assembly 85 of preferred modified HDD assembly 30 in a 45 angle slant
subsurface drilling
position with drill pipe 100 in a horizontal stored position. The preferred
pivoting hinge 70 is
shown in a lowered position. As shown in Figure 6, modified HDD assembly 30
includes power
unit 32 (power unit 34 not shown), rotary and carriage assembly 40, thrust
frame 42, frame
hydraulic cylinder 44, breakout wrench assembly 50, bushing assembly 60,
pivoting hinge 70,
sub-structure 80, slip assembly 85, drill pipe and casing handler 90, handler
hydraulic cylinder
92, drill pipe 100 and leveling jacks 110. Further, as shown in Figure 6,
rotary and carriage
assembly 40 and thrust frame 42 of preferred modified HDD assernbly 30 are
adapted to be
pivotally rotated from a position approximately parallel to the drilling
surface (as shown in
Figures 1 and 2) to a position approximately 45 from the horizontal drilling
surface in order to
perform slant subsurface drilling applications. Rotary and carriage assembly
40 and thrust frame
42 are preferably moved between an approximately horizontal position and a
position
approximately 45 from the horizontal drilling surface by frame hydraulic
cylinder 44.
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Referring now to Figure 7, a side view of the preferred modified HDD assembly
30 is illustrated.
More particularly, Figure 7 illustrates preferred modified HDD assembly 30,
rotary and carriage
assembly 40, breakout wrench assembly 50, guide bushing assembly 60, slip
assembly 85 and
preferred drill pipe 100 in a 45 angle slant subsurface drilling position.
The preferred pivoting
hinge 70 is shown in a lowered position. As shown in Figure 6, modified HDD
assembly 30
includes power unit 32 (power unit 34 not shown), rotary and carriage assembly
40, thrust frame
42, frame hydraulic cylinder 44, breakout wrench assembly 50, bushing assembly
60, pivoting
hinge 70, sub-structure 80, slip assembly 85, drill pipe and casing handler
90, handler hydraulic
cylinder 92, drill pipe 100 and leveling j acks 110. Further, as shown in
Figure 6, drill pipe and
casing handler 90 and drill pipe 100 are adapted to be pivotally rotated from
a position
approximately parallel to the drilling surface (as shown in Figures 1, 2, 3
and 6) to a position
approximately 45 from the horizontal drilling surface in order to perform
slant subsurface
drilling applications. Drill pipe and casing handler 90 and drill pipe 100 are
preferably moved
between an approximately horizontal position and a position approximately 135
from the
horizontal drilling surface by handler hydraulic cylinder 92.
Referring now to Figure 8, a side view of rotary and carriage assembly 40 of
the preferred
embodiment of modified HDD assembly 30 is illustrated. The preferred rotary
and carriage
assembly 40 is adapted to apply thrust and pull-back forces to a drill pipe or
casing or a string of
drill pipes or casings through a combination of pinion drive planetary
gearboxes and hydraulic
motors. More particularly, as shown,in Figure 8, preferred rotary and carriage
assembly 40
includes carriage drive planetary gearboxes 140 and carriage drive motors 142.
The preferred
rotary and carriage assembly further includes rotary gearbox planetary
gearboxes 144, rotary
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gearbox hydraulic motors 146 and rotary gearbox output spindle 148. The
preferred rotary
gearbox and the preferred output spindle applies rotational torque to a drill
pipe or a string of
drill pipes. While Figure 8 illustrates hydraulic motors adapted to provide a
power source to the
preferred rotary and carriage assembly, it is contemplated within the scope of
the invention that
the rotary and carriage assembly may be powered by and suitable power source
such as an
electric motor and the like.
Referring now to Figure 9, a top vieNN, of preferred rotary and carriage
assembly 40 is illustrated.
As shown in Figure 9, preferred rotary and carriage assembly 40 includes
camage drive
planetary gearboxes 140 and carriage diive motors 142. The preferred rotary
and carriage
assembly further includes rotary gearbox planetary gearboxes 144, rotary
gearbox hydraulic
motors 146 and rotary gearbox output spindle 148. In addition, preferred
rotary and carriage
assembly 40 includes telescoping slip spindle sub assembly 150 which is
described in more
detail below.
Referring now to Figure 10, a partial sectional side view of the preferred
telescoping slip spindle
sub assembly 150 of the preferred embodiment of modified HDD assembly 30 is
illustrated.
More particularly, Figure 10 illustrates preferred slip spindle sub assembly
150 with output
spindle 148 in a retracted condition. As shown in Figure 10, preferred slip
spindle sub assembly
150 includes output spindle 14S, drive sleeve 154 and housing 156. The
preferred output spindle
148 is adapted to extend and retract in a telescoping manner depending upon
the direction of the
thrust loading applied to the rotary and carriage assembly. Preferably, the
output spindle axially
extends from and axially retracts into housing 156 a distance of approximately
four inches. The
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preferred drive sleeve 154 engages preferred output spindle 148 so as to
transmit rotational
torque from slip spindle input end 158 to slip spindle output end 160. The
preferred slip spindle
sub assenibly reduces damage and wear to the drill pipe and casing thread
extends the life of drill
pipe tool joint connections threads as a result of the telescoping action of
output spindle 148.
Referring now to Figure 11, a partial sectional side view of the preferred
telescoping slip spindle
sub assembly 150 of the preferred embodiment of modified HDD assembly 30 is
illustrated.
More particularly, Figure 11 illustrates preferred slip spindle sub assembly
150 with output
spindle 148 in an extended condition. As sliown in Figure 11, preferred slip
spindle sub
assembly 150 includes output spindle 148, drive sleeve 154, housing 156, input
end 158 and
output end 160.
Referring now to Figure 12, a cross-sectional view of the preferred
telescoping slip spindle sub
assembly 150 of the preferred embodiment of modified HDD assembly 30 is
illustrated. More
particularly, as shown in Figure 12, preferred slip spindle sub assembly 150
includes output
spindle 148, drive sleeve 154 and housing 156.
Referring now to Figure 13, a side view of a first alternative embodiment of
the modified
horizontal directional drilling assembly is illustrated. More particularly,
the preferred modified
horizontal directional drilling assembly 230 includes fixed pivot 270 and wide
stnit system 280.
The preferred fixed pivot 270 is adapted to permit tlirust frame 242 to be
pivotally moved
between a position that is substantially parallel to the drilling surface and
a position that is
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substantially perpendicular to the drilling surface. Preferably, fixed pivot
270 is adapted to
pennit thrust frame 242 to be moved through an approximately 90 angle.
Refeiring now to Figures 13 and 14, the prefeiTed wide strut system 280 is
adapted to provide
stability to the drilling assembly. The preferred wide strut system includes a
pair of wide strut
system arms 282, each of which have a thnist franle end 283 attached to thrust
frame 242 and an
anchoring end 284 adapted to be anchored to sub-structure 280. While the wide
strut system
illustrated in Figures 13 and 14 includes a pair of arms, it is contemplated
within the scope of the
invention that the wide strut system may include more or less than two arms.
It is also
contemplated within the scope of the invention that the anchoring end of the
arms may be
anchored to any suitable support structure, including but not limited to, the
drilling surface.
Further, although the wide strut system illustrated in Figures 13 and 14 shows
the thrust frame in
a substantially vertical position, it is contemplated within the scope of the
invention that the wide
strut system may be adapted for use when the thrust frame is not in a
substantially vertical
position.
Referring now to Figure 15, a top view of an alternative embodiment of the
rotary and carriage
assembly of the preferred modified horizontal directional drilling assembly of
the present
invention is illustrated. The preferred rotary and carriage assembly is
designated generally by
reference numeral 340. The preferred rotary and carriage assembly 340 is
adapted to for use in
connection with tube-in-tube drill pipes and tube-in-tube drill pipe strings.
More particularly, the
preferred rotary and carriage assembly 340 is adapted to pump fluid (such as
bentonite, air, water
and the like) through the annular channel located between the inner tube and
the outer tube of a
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.. .. ..
tube-in-tube drill pipe toward the cutting tool (such as a percussion hammer)
of the drill pipe
string. In such a tube-in-tube drill pipe application, the fluid punlped
through the annular
channel of the drill pipe actuates the cutting tool, removes cuttings from the
face of the cutting
tool, and directs the cuttings into the inner tube for discharge to the
drilling surface. 'Figure 15A
illustrates in detail the flow of fluid and cuttings (represented by arrowed
lines 340A and 340B,
respectively) through the lower portion of the rotary and carriage assembly.
Figure 15A also
clearly illustrates the preferred center cuttings discharge hose 340C which is
adapted to convey
cuttings from the inner tube of a tube-in-tube drill pipe (or tube-in-tube
drill pipe string) to the
cuttings discharge tube 370, which is described below.
As shown in Figures 15 and 16, the preferred rotary and carriage assembly 340
includes carriage
drive planetary gearbox 341, rotary gearbox hydraulic motor 346, rotary
gearbox output spindle
348 and telescoping slip spindle sub assembly 350. In addition, the preferred
rotary and carriage
assembly 340 includes plumbing adapted to convey fluid to the annular channel
betvcleen the
inner tube and the outer tube of a tube-in-tube drill pipe and/or a tube-in-
tube drill pipe string.
The preferred rotary and carriage assembly 340 includes plumbing adapted to
convey cuttings
-from the inner tube of the tube-in-tube drill pipe out of the drilling
assembly. More particularly,
in the preferred rotary and carriage assembly, fluid inlet tube 360 is
connected to below rotary
side inlet swive1362 such that fluid in conveyed to the annular channel
between the inner tube
and the outer tube of a tube-in-tube drill pipe. Preferably, an inlet hanuner
union 364 or some
other suitable connection device is located at the upstream end of the fluid
inlet tube. Also in the
preferred rotary and carriage assembly, cuttings discharge tube 370 is
connected to above rotary
swive1372 such that cuttings from the inner tube of the tube-in-tube drill
pipe may be conveyed
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out of the assembly. The preferred discharge tube 370 also includes discharge
hammer union
374 or some other suitable connecting device. While the preferred fluid inlet
tube 360 and the
preferred cuttings discharge tube 370 are illustrated in their preferred
configuration and
arrangement, it is contemplated within the scope of the invention that the
tubes may be any
suitable configuration and they may be located in any suitable arrangement.
In operation, several advantages of the apparatus and method of the invention
are realized. For
example, the drilling assembly of the invention produces an increased capacity
for drill pipe
rotational, tlu-ust and pull-back forces. The drilling assembly of the
invention is capable of
producing longer well bores and well bores having a greater diameter than
those produced by
conventional drilling assemblies. The drilling assembly of the invention is
capable of entering
the earth and drilling a well bore at any angle between approximately parallel
to a horizontal
drilling surface to a 90 vertical angle. Consequently, the drilling assembly
of the invention is
capable of drilling at an angle steeper than conventional horizontal
directional drill assemblies
and at an angle closer to horizontal than conventional vertical drill
assemblies. The anchoring
system and rotary and carriage assembly of the preferred drilling assembly of
the invention
eliminate the need for heavy drill pipe or drill collars in order to exert
downward force on the
drill bit. The drilling assembly of the invention is more easily transported
than conventional
drillin~ assemblies as a result of on-board power units and the reduced weight
of the assembly.
The rack and pinion rotary and carriage assembly of the drilling assembly of
the invention
eliminates the need for cables, winches, hydraulic cylinders, chain systems
and the like to
provide rotational, thrust and pull-back forces. The slip assembly of the
preferred drilling
assembly of the invention also reduces damage and wear to the threaded end of
a drill string
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section when the top drive or rotary table engages the threaded end of the
drill string section.
The drilling assembly of the invention further reduces the amount of time
required to perform
make-up and break-out operations on the drill pipe and/or casing tool joints.
The arms of the
pipe and casing handler of the invention, which are pinned to the sub-
structure, allow for easy
removal during transport. The diilling assembly of the invention is also
adapted to perform
vertical and horizontal directional drilling applications with a tube-in-tube
drill pipe and a tube-
in-tube drill pip string. In addition, in the event of a power unit failure,
the drilling assembly of
the invention may continue to be operated as a result of the plurality of
power units provided
(run-on-one-technology).
Although this description contains many specifics, these should not be
construed as limiting the
scope of the invention but as merely providing illustrations of some of the
presently preferred
embodiments thereof as well as the best mode contemplated by the inventor of
carrying out the
invention. The invention, as described herein, is susceptible to various
modifications and
adaptations, and the same are intended to be comprehended within the meaning
and range of
equivalence of the appended claims.
What is claimed is:
