U.S. patent application number 10/496631 was filed with the patent office on 2005-01-13 for method and apparatus for through rotary sub-sea pile-driving.
Invention is credited to Bell, Douglas B, Gray-Stepehns, Malcolm G.S., Mueller, Dan T..
Application Number | 20050006105 10/496631 |
Document ID | / |
Family ID | 32474555 |
Filed Date | 2005-01-13 |
United States Patent
Application |
20050006105 |
Kind Code |
A1 |
Bell, Douglas B ; et
al. |
January 13, 2005 |
Method and apparatus for through rotary sub-sea pile-driving
Abstract
A method and apparatus for driving a pile are disclosed. The
pile-driving apparatus comprises a pile, a shoe tip coupled to a
toe of the pile, and a drill string disposed within the pile. The
drill string comprises a gripping device coupling the drill string
to the pile and a hammer deployed into the pile such that the
hammer is capable of transmitting a force to the shoe tip. The
method, comprises positioning a hammer in a pile such that the
hammer is capable of transmitting a force to a shoe tip;
positioning, in the pile, a portion of drill pipe having a gripping
device to engage the pile; and deploying the pile beneath the
surface of a body of water.
Inventors: |
Bell, Douglas B; (Dubai,
AE) ; Mueller, Dan T.; (Cypress, TX) ;
Gray-Stepehns, Malcolm G.S.; (Aberdeen, GB) |
Correspondence
Address: |
WILLIAMS, MORGAN & AMERSON, P.C.
10333 RICHMOND, SUITE 1100
HOUSTON
TX
77042
US
|
Family ID: |
32474555 |
Appl. No.: |
10/496631 |
Filed: |
May 21, 2004 |
PCT Filed: |
December 1, 2003 |
PCT NO: |
PCT/US03/38022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60430195 |
Dec 2, 2002 |
|
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|
60437807 |
Jan 3, 2003 |
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Current U.S.
Class: |
166/381 ;
166/242.1 |
Current CPC
Class: |
E21B 4/20 20130101; E21B
7/20 20130101; E21B 4/06 20130101; E02D 27/52 20130101; E02D 7/30
20130101; E21B 4/14 20130101 |
Class at
Publication: |
166/381 ;
166/242.1 |
International
Class: |
E21B 023/00 |
Claims
What is claimed:
1. A pile-driving apparatus, comprising: a pile; a shoe tip coupled
to a toe of the pile; and a drill string, the drill string
including a hammer coupled to the pile such that the hammer is
capable of transmitting a force to the shoe tip.
2. The apparatus of claim 1, wherein the pile comprises a casing
string, a deep water pile, a shallow water pile, a PLEM pile; a
sub-sear template, a manifold pile, a tension leg platform anchor
pile and a drill rig mooring pile.
3. The apparatus of claim 1, wherein the shoe tip includes a
membrane covering.
4. The apparatus of claim 1, wherein the shoe tip is coupled to the
pile interior.
5. The apparatus of claim 1, wherein the shoe tip is coupled to the
pile exterior.
6. The apparatus of claim 1, wherein the hammer is coupled to the
pile at the top thereof.
7. The apparatus of claim 1, wherein the hammer is coupled to the
pile at the toe thereof.
8. The apparatus of claim 1, wherein the hammer is a percussive
hammer.
9. The apparatus of claim 8, wherein the percussive hammer
comprises a hydraulic hammer.
10. The apparatus of claim 1, wherein the drill string further
includes a gripping device by which the drill string is coupled to
the pile.
11. The apparatus of claim 10, wherein the gripping device couples
the drill string to the pile at the top of the pile.
12. The apparatus of claim 1, wherein the drill string includes a
plurality of wings by which the hammer is coupled to the pile via a
sling.
13. The apparatus of claim 1, further comprising an external
gripping device by which the hammer is coupled to the pile via a
sling.
14. The apparatus of claim 8, wherein the percussive hammer is a
rotation powered hammer.
15. An apparatus, comprising: a pile; a shoe tip deployed at a tip
of the pile; and a hammer coupled to the pile such that the hammer
is capable of transmitting a force to the shoe tip.
16. The apparatus of claim 15, further comprising a portion of
drill pipe having a lockable telescoping section deployed in the
pile.
17. The apparatus of claim 15, wherein the pile includes a shoe
joint capable of receiving the force from the hammer and
transmitting said force to the shoe tip.
18. The apparatus of claim 15, wherein the hammer comprises a
percussive hammer.
19. The apparatus of claim 15, further comprising a valve system to
direct a fluid to at least one of the shoe tip and the pile.
20. The apparatus of claim 15, further comprising a gripping device
coupled to the hammer and coupled to the pile; and
21. The apparatus of claim 15, further comprising a sling by which
the hammer is coupled to the pile.
22. The apparatus of claim 15, further comprising an external
gripping device by which the hammer is coupled to the pile via a
sling.
23. A method, comprising: positioning a hammer relative to a pile
such that the hammer is capable of transmitting a force to a shoe
tip; positioning a portion of drill pipe to engage the pile; and
deploying the pile beneath the surface of a body of water.
24. The method of claim 23, wherein deploying the pile comprises
deploying pile such that the shoe tip is in contact with a first
selected location on a floor of the body of water.
25. The method of claim 23, wherein positioning the hammer includes
positioning the hammer such that the hammer is capable of
transmitting a force directly to the shoe tip
26. The method of claim 23, wherein positioning the hammer includes
positioning the hammer such that the hammer is capable of
transmitting a force indirectly to the shoe tip
27. An apparatus, comprising: means for positioning a hammer
relative to a pile such that the hammer is capable of transmitting
a force to a shoe tip; means engaging the hammer to the pile; and
means for deploying the pile beneath the surface of a body of
water.
28. The apparatus of claim 27, further comprising means for
transmitting a force from the hammer to the shoe tip such that the
shoe tip penetrates the floor at the first selected location.
29. The apparatus of claim 27, further comprising means for
providing a lubricating fluid proximate the shoe tip.
30. A method for deploying a pile-driving apparatus, the method
comprising: rigging up the pile-driving apparatus; and deploying
the rigged-up pile-driving apparatus through the rotary of a
drilling rig.
31. The method of claim 30, wherein rigging up the pile-driving
apparatus includes: positioning a percussive hammer in a pile such
that the percussive hammer is capable of transmitting a force to a
shoe tip; and positioning the drill pipe to engage the pile.
32. The method of claim 30, wherein deploying the rigged-up
pile-driving apparatus through the rotary of the drilling rig
includes deploying the rigged-up pile-driving apparatus through a
rotary of a mobile offshore drilling unit.
33. The method of claim 30, further comprising single tripping the
rigged-up pile-driving apparatus to the seabed.
34. A method for deploying a pile-driving apparatus, the method
comprising: deploying the pile-driving apparatus; and single
tripping the rigged-up pile-driving apparatus to the seabed.
35. The method of claim 34, wherein rigging up the pile-driving
apparatus includes: positioning a percussive hammer relative to a
pile such that the percussive hammer is capable of transmitting a
force to a shoe tip; and positioning, in the pile, a portion of
drill pipe having a gripping device to engage the pile.
36. The method of claim 34, wherein deploying the rigged-up
pile-driving apparatus through the rotary of the drilling rig
includes deploying the rigged-up pile-driving apparatus through a
rotary of a mobile offshore drilling unit.
37. The method of claim 34, further deploying the rigged-up
pile-driving apparatus through the rotary of a drilling rig.
38. An apparatus, comprising: a plurality of casing joints; a shoe
tip deployed at a tip of a first one of the plurality of casing
joints; a percussive hammer deployed with the casing joints such
that the percussive hammer is capable of transmitting a force to
the shoe tip; a gripping device coupled to the percussive hammer
and coupled to the casing joints; and a portion of drill pipe
coupled to the plurality of casing joints via the gripping device
and capable of deploying the casing joints beneath the surface of a
body of water.
39. The apparatus of claim 38, further comprising a portion of
drill pipe having a lockable telescoping section deployed in the
plurality of casing joints.
40. The apparatus of claim 38, wherein the first one of the
plurality of casing joints is a shoe joint capable of receiving the
force from the percussive hammer and transmitting said force to the
shoe tip.
41. The apparatus of claim 38, wherein the percussive hammer
comprises a hydraulic percussive hammer.
42. The apparatus of claim 38, wherein the percussive hammer
comprises a rotary percussive hammer.
43. The apparatus of claim 38, further comprising a valve system to
direct a fluid to at least one of the shoe tip and the plurality of
casing joints.
44. The apparatus of claim 38, wherein the percussive hammer is
capable of transmitting a force directly to the shoe tip
45. The apparatus of claim 38, wherein the percussive hammer is
capable of transmitting a force indirectly to the shoe tip
46. A method, comprising: positioning a percussive hammer in a
first one of a plurality of casing joints such that the percussive
hammer is capable of transmitting a force to a shoe tip;
positioning, in the plurality of casing joints, a portion of drill
pipe having a gripping device to engage the casing joints; and
deploying the plurality of casing joints beneath the surface of a
body of water.
47. The method of claim 46, wherein deploying the plurality of
casing joints comprises deploying the casing joints such that the
shoe tip is in contact with a first selected location on a floor of
the body of water.
48. The method of claim 46, wherein positioning the percussive
hammer includes positioning the percussive hammer such that the
percussive hammer is capable of transmitting a force directly to a
shoe tip
49. The method of claim 46, wherein positioning the percussive
hammer includes positioning the percussive hammer such that the
percussive hammer is capable of transmitting a force indirectly to
a shoe tip
50. An apparatus, comprising: means for positioning a percussive
hammer in a first one of a plurality of casing joints such that the
percussive hammer is capable of transmitting a force to a shoe tip;
means engaging the percussive hammer to the casing joints; and
means for deploying the plurality of casing joints beneath the
surface of a body of water.
51. The method of claim 50, further comprising means for
transmitting a force from the hammer to the shoe tip such that the
shoe tip penetrates the floor at the first selected location.
52. The method of claim 50, further comprising means for providing
a lubricating fluid proximate the shoe tip.
53. A pile-driving apparatus, comprising: a casing string; and a
drill string disposed within the casing string, the drill string
comprising: a gripping device coupling the drill string to the
casing string; a percussive hammer deployed into the casing joints
such that the percussive hammer is capable of transmitting a force
to the shoe tip; and a shoe tip deployed at a tip of a first one of
the plurality of casing joints.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to underwater pile-driving,
and, more particularly, to through rotary sub-sea pile-driving.
[0003] 2. Description of the Related Art
[0004] Sub-sea, sometimes called "subsurface" in the sense of being
under the surface of the water, pile-driving may be used to drill
into the sediment at the bottom of a variety of underwater
environments. For example, sub-sea pile-driving may be used to
facilitate the installation of offshore production structures such
as sub-sea platform skirt piles, sub-sea templates, drilling
conductors, sub-sea manifolds, and the like. Sub-sea pile-driving
may be performed in shallow water, typically less than 150 meters
in depth, or in deep water.
[0005] The pile-driving apparatus typically includes a hammer,
which drives a guide shoe tip into the sediment. The hammer and
guide shoe tip are typically suspended from a platform by a crane
or some cables, or, alternatively, a drill string and an umbilical.
In various embodiments, the umbilical provides air, electricity,
and hydraulic oil to the hammer, as well as retrieving the used
hydraulic oil from the hammer. Examples of rigs used in sub-sea
pile-driving include jack-up rigs, derrick barges, submersible
rigs, semi-submersible rigs, drill ships, and the like. These types
of rigs are sometimes referred to as mobile offshore drilling units
("MODUs").
[0006] Conventional sub-sea pile-driving methods suffer from a
number of disadvantages. For example, friction from the sediment
beneath the mud line may reduce the penetration depth of the guide
shoe tip. For yet another example, sub-sea pile-driving typically
uses hydraulic oil, which may leak or spill into the undersea
environment. Reels used to store and deploy the umbilical used to
provide and retrieve the hydraulic oil may also consume valuable
deck space on the platform. Furthermore, conventional pile-driving
techniques may be limited to shallow water applications, at least
in part because of the large hydraulic pressure that must be
supplied to the hammer.
SUMMARY OF THE INVENTION
[0007] The invention comprises, in its various aspects and
embodiments, an method and apparatus for driving a pile. The
pile-driving apparatus comprises a pile, a shoe tip coupled to a
toe of the pile, and a drill string disposed within the pile. The
drill string comprises a gripping device coupling the drill string
to the pile and a hammer deployed into the pile such that the
hammer is capable of transmitting a force to the shoe tip. The
method, comprises positioning a hammer in a pile such that the
hammer is capable of transmitting a force to a shoe tip;
positioning, in the pile, a portion of drill pipe having a gripping
device to engage the pile; and deploying the pile beneath the
surface of a body of water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention may be understood by reference to the
following description taken in conjunction with the accompanying
drawings, in which like reference numerals identify like elements,
and in which:
[0009] FIG. 1 conceptually illustrates, in an assembled,
partially-sectioned, plan view of one embodiment of an apparatus in
accordance with the present invention;
[0010] FIG. 2 conceptually illustrates a portion of the deployment
of the pile-driving apparatus of FIG. 1 in one particular
embodiment;
[0011] FIG. 3 illustrates a shoe joint for the apparatus of FIG. 1,
including an optional membrane covering the end thereof;
[0012] FIG. 4 depicts a clamp for clamping an umbilical of the
apparatus of FIG. 1 to the drill string thereof;
[0013] FIG. 5 illustrates a first percussive hammer as may be used
in the apparatus of FIG. 1, the percussive hammer being a nitrogen
cap hydraulic percussive hammer, with control umbilical;
[0014] FIG. 6 illustrates a second percussive hammer as may be used
in alternative embodiments of the present invention, the percussive
hammer being an automatic reciprocating hydraulic percussive
hammer;
[0015] FIG. 7 illustrates a port collar;
[0016] FIG. 8 depicts a telescoping pipe joint as may be employed
in the embodiment of FIG. 1;
[0017] FIG. 9 depicts a filtration for a filter sub as may be used
in some alternative embodiments of the present invention;
[0018] FIG. 10 depicts a gripping device that may be used to couple
the drill pipe of the apparatus in FIG. 1 to the pile thereof;
[0019] FIG. 11A-FIG. 11D illustrates one particular embodiment of
the pile-driving apparatus in FIG. 1; and
[0020] FIG. 12A-FIG. 12D illustrate a second particular embodiment
of the pile-driving apparatus in FIG. 1 alternative to the
embodiment in FIG. 11A-FIG. 11D.
DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS
[0021] Illustrative embodiments of the invention are described
below. In the interest of clarity, not all features of an actual
implementation are described in this specification. It will of
course be appreciated that in the development of any such actual
embodiment, numerous implementation-specific decisions must be made
to achieve the developers' specific goals, such as compliance with
system-related and business-related constraints, which will vary
from one implementation to another. Moreover, it will be
appreciated that such a development effort might be complex and
time-consuming, but would nevertheless be a routine undertaking for
those of ordinary skill in the art having the benefit of this
disclosure.
[0022] The present invention relates to a method and apparatus for
single journey conveyance of a sub-sea pile-driving device from the
surface of a body of water to the sea floor, and the subsequent
concussive installation of sub-sea caissons, tubular piles, and/or
surface sections of well casing using the sub-sea pile-driving
device. The sub-sea pile-driving device may, in various
embodiments, be used in either shallow water or deep water
environments. The caissons or tubular piles may, in one embodiment,
be used to attach various structures to the sea floor. Examples of
the various structures include sub-sea platform skirt piles,
sub-sea templates, drilling conductors, sub-sea manifolds, and the
like. The well casing is generally used for providing a stable
foundation for drilling oil wells at depths in excess of 600'.
[0023] FIG. 1 conceptually illustrates, in an assembled,
partially-sectioned plan view, one embodiment of a pile-driving
apparatus 100 in accordance with the present invention. The
pile-driving apparatus 100 comprises a pile 103, a shoe tip 106
coupled to a toe 109 of the pile 103, and a drill string 112
disposed within the pile 103. The drill string 112 includes a
gripping device 115 and a percussive hammer 118. The gripping
device couples the drill string 112 to the pile 106.
[0024] The percussive hammer 118 is deployed into the pile 106 such
that the percussive hammer 118 is capable of transmitting a force
to the shoe tip 106 directly or indirectly. Some embodiments are
"toe-driven." In these embodiments, the shoe tip 106 is coupled to
the pile 103 at the toe 109 thereof, such that the percussive
hammer 118 delivers the force directly to the shoe tip 106 at the
toe 109. Some embodiments are "top-driven." In these embodiments,
the shoe tip 106 is coupled to the top 121 of the pile 103 such
that the percussive hammer 118 delivers the force indirectly to the
shoe tip 106 at the top 121. The embodiment in FIG. 1 is
toe-driven.
[0025] FIG. 2 conceptually illustrates a portion of the deployment
of the pile-driving apparatus 100 in one particular embodiment. In
FIG. 2, the pile-driving apparatus 100 is deployed from a
semi-submersible rig 200 after rig-up. However, the rig 200 may be
any of a variety of MODUs, including, but are not limited to,
jack-up rigs, semi-submersible rigs, and drill ships. The drill
string (also known as a drill pipe column) is generally used to
suspend the pile 103 from the rig 200 and deploy the pile 103
beneath the surface 206 of a body of water 209. In one embodiment,
the casing is suspended from the rig by the drill string and
descends through the rotary table as additional stands of drill
pipe are added. Suitable rigs may include, but are not limited to,
jack-up rigs, semi-submersible rigs, and drill ships. The
pile-driving apparatus 100 is suspended from the rig 200 by the
drill string 112 and lowered to the sea floor 215. On contact with
the sea floor 215, the operation of the percussive hammer 118
delivers the force, directly or indirectly, to the shoe tip 106.
Because the shoe tip 106 is coupled to the pile 103, the force of
the impact is transferred through the shoe tip 106 to the pile 103
to drive the pile 106 into the sea floor 215. Note that, in this
description, the labels "toe" and "top" are defined relative to the
orientation of the pile-driving apparatus 100 during deployment, as
shown in FIG. 2.
[0026] Returning to FIG. 1, as previously noted, the pile-driving
apparatus 100 shown therein is but one embodiment and the invention
admits variation in the implementation of the apparatus of the
invention. One such variation was previously mentioned, i.e., the
apparatus may be toe-driven or top-driven. Another such variation
is the nature of the pile 103. In the embodiment of FIG. 1, the
pile 103 comprises a surface casing installation or a deep water
conductor. In the interest of clarity, the term "casing" will
hereinafter be understood to refer to either a surface casing
installation or a deep water conductor. In this particular
embodiment, the casing includes a plurality of casing joints.
[0027] Also in the embodiment of FIG. 1, the shoe tip 106 is
deployed in the pile 103 and the percussive hammer 118 is deployed
in the pile 103 such that the percussive hammer 118 is capable of
transmitting a force to the shoe tip 106. For example, in one
embodiment, the shoe tip 106 may be deployed in one casing joint. A
vocationally designed, or implementation specific, shoe joint 300,
shown in FIG. 3, is provided in the casing to accept energy
transfer, i.e., the aforementioned force, from the percussive
hammer 118 and transmit the force to the guide shoe tip 106. In one
embodiment, the shoe joint 300 may include a membrane 303, also
shown in FIG. 3, to prevent ingress of material from the sea floor
215 during self-penetration. In one embodiment, the shoe joint 300
may allow subsequent piles 103 to pass through by hammering or
drilling while closing the pile 103.
[0028] The percussive hammer 118 in the embodiment of FIG. 1 is a
hydraulic hammer. The percussive hammer 118 may receive hydraulic
oil provided by an umbilical 127 to generate the force that is used
to drive the shoe tip 106 into the sea floor 215, shown in FIG. 2.
The umbilical 127 may be coupled to the drill string 112 by quick
attach and release clamps, such as the clamp 400 in FIG. 4.
Alternatively, the percussive hammer 118 may employ ambient water,
or other fluids such as soapy water as described further below, to
generate the force that is used to drive the shoe tip 106 into the
sea floor 215. The percussive hammer 118 in this embodiment is
generally controlled by signals transmitted via the umbilical
127.
[0029] The percussive hammer 118 of FIG. 1, shown in greater detail
in FIG. 5, is an accelerated fluid driven hammer controlled by
signals conveyed by umbilical 127 from the surface. The hydraulic
fluid is, in this particular embodiment, derived from the ambient
seawater. The tip 503 of the percussive hammer 118 displaces soil
and the pile 103 is pulled down by the engagement ring, thus
following the percussive hammer 118 into the sea floor 215, shown
in FIG. 2, and through the formation in question. The percussive
hammer 118, in one implementation of this particular embodiment, is
an IHC S-90 hydraulic hammer, commercially available from BJ
Services, Inc. at:
[0030] Hareness Circle
[0031] Altens, Aberdeen AB1 4YL
[0032] United Kingdom
[0033] Phone: 44-1224-249-678
[0034] Fax: 44-1224-249-106
[0035] Email enquiries.tubular@bjservices.co.uk
[0036] Other suitable hydraulic percussive hammers known to the art
may be employed.
[0037] However, the percussive hammer 118 need not be hydraulic in
all embodiments. For instance, the percussive hammer 118 may also
be rotated from the rig 200, in FIG. 2, by the drill string 112.
The rotational percussive hammer may engage the pile 103 through a
landing ring (not shown) in a shoe joint (also not shown) of the
pile 103. The hole would be bailed by return of fluids (e.g.,
seawater derived) discharged thru the top 121 of the pile 103 to
open ocean or via a port collar, such as the port collar 130, first
shown in FIG. 1 and best shown in FIG. 7, to sea floor 215 that can
be closed after drive is completed. The automatic reciprocating
percussion hammer may be implemented using, for instance, the
automatic reciprocating percussion hammer sold as the Fluid Hammer
185 mud hammer, available from
[0038] SDS Digger Tools, Pty., Ltd.
[0039] 49 Vulcan Road
[0040] Canning Vale, Western Australia 6155.
[0041] Note this hammer is relatively small and is primarily
suitable driving relatively small piles, eg. 30' piles in soft
conditions with the feeble existing item. Rotational percussive
hammers used as drilling tools for pulling casing in by drilling
with drill bits, as opposed to piling, may also be adapted to toe
drive.
[0042] In several instances above, reference is made to the use of
ambient seawater in various embodiments of the invention. In those
embodiments, the seawater is filtered by, for example, a filtration
unit 900, shown in FIG. 9, of a filter sub (not otherwise shown)
assembled into the drill string 112. The seawater ingresses the
filtration unit 900 from the top 903 thereof, is filtered by the
filter screen 906 within the filter housing 909, and egresses
through the bottom 912. The filtration unit 900 also includes a
plug 915. Some embodiments may employ multiple filtration units
900. The position of the filtration unit(s) 900 within the drill
string 112 will be implementation specific, but will generally be
above the hammer 118. The seawater would also be filtered prior to
entry into the drill string. Thus, in some alternative embodiments,
pressurized ambient seawater is conveyed via the drill string 112
and provided to the percussive hammer 118.
[0043] Various other fluids may be provided to the percussive
hammer 118 in assorted alternative embodiments. In one embodiment,
the umbilical 127 provides hydraulic oil to the percussive hammer
118. The umbilical may also retrieve the hydraulic oil. In one
embodiment, lubricating fluids may be provided to the percussive
hammer 118 via the umbilical or, alternatively, via the drill
string 112. The lubricating fluids may include, but are not limited
to, soapy water, coco fatty ketaine, various ethoxylated compounds
such as alkyl phenols, fatty alcohols, amines, amides, diamines,
quaternary ammonium chlorides, as well as sulphonated naphthalene
formaldehyde condensate, sulfonated styreiemaleic anhydrides, and
various polyacrylamides. The lubricating fluids may be used to
reduce friction between the formation and the pile/casing.
Additional fluids that may be provided to the percussive hammer are
described in U.S. Pat. No. 5,748,665, U.S. Pat. No. 5,020,598, U.S.
Pat. No. 5,016,711, and U.S. Pat. No. 5,284,513, which are
incorporated herein by reference.
[0044] A diverter valve system (not shown) may, in various
embodiments, be used to direct the flow of the fluids. For example,
the diverter valve system may redirect hydraulic fluid, such as the
ambient seawater, to the toe of the shoe joint. Alternatively, the
diverter valve system may be used to direct the hydraulic fluid,
such as the ambient seawater, back into the pile 103 for eventual
return to the surface of the sea floor 215 or the surrounding body
of water. Filter systems may also be included in the drill string
for filtering the various fluids. For example, sea water may be
filtered as it passes into and/or out of the drill string 112.
[0045] Thus, any given embodiment may use one or more of the
following fluid conveyance techniques:
[0046] for deep-water applications it is considered feasible to
utilize the drill pipe column to carry the fluid to the Percussion
device in question;
[0047] in certain instances it may practical to use coil tubing in
either concentric or single tube configuration;
[0048] filtration media can be introduced by virtue of filter subs
at strategic and readily accessible points in the conveyance
system; and
[0049] for shallow water jack-up installations, any of the above or
standard hydraulic hoses can be considered.
[0050] Still other fluid conveyance techniques known to the art may
be employed in alternative embodiments.
[0051] Vocationally designed, or implementation specific, adaptor
sub and/or crossover components (not shown) may also be included in
the casing to merge individual items into the operational system.
As is well known in the art, the assembly of drill strings
frequently utilize adaptors, crossovers, etc. to line up
connections and to provide interfaces between tools and pieces of
pipe. Also, the use of these types of components is implementation
specific, as the design for any given drill string will be unique
for the given goals and conditions. The drill string 112 of the
present invention, shown in FIG. 1, employs these types of
components in accordance with conventional practice.
[0052] Returning to FIG. 1, in the illustrated embodiment, the
surface casing installation may also include one or more telescopic
drill pipe sections 124, shown in greater detail in FIG. 8. The
telescopic drill pipe sections 124 may be used to position the
percussive hammer 118 within the pile 103. In one embodiment, the
telescopic drill pipe sections 124 are capable of being locked and
unlocked. In one embodiment, the telescopic drill pipe sections 124
may be locked and/or unlocked by rotating the drill string 112
coupled to the pile 103. However, it will be appreciated that the
telescopic drill pipe sections 124 are not necessary for the
practice of the present invention. In alternative embodiments, a
variety of hammer suspension systems, such as slings and the like,
may also be used to position the percussive hammer 118 within the
pile 103.
[0053] As previously mentioned a drill pipe section having a
gripping device 115, shown best in FIG. 10, is also deployed in the
pile 103. The gripping device 115 is set and/or unset by the
rotation of the drill string 112. The gripping device 115 is
substantially coupled to the pile 103 and holds the pile 103
substantially fixed with respect to the drill string 112. In the
present context, the term "substantially" is used to indicate that,
in the practice of the present invention, the gripping device 115
may not hold the pile 103 perfectly fixed with respect to the drill
string 112. Those of ordinary skill in the art having the benefit
of this disclosure will appreciate that the gripping device 115 may
allow some movement of the pile 103 with respect to the drill
string 112 during operation of the present invention. The amount of
movement is a matter of design choice and not material to the
present invention. The gripping device 115 will typically engage
the hammer 118 to the pile 103 at the top of the pile 103, but this
is not necessary to the practice of the invention. The gripping
device 115 may engage the hammer 118 to the pile 103 at the bottom
of the pile 103, but additional support devices, such as slings,
etc. may be desirable to support the weight of the pile 103 and
drill string 112.
[0054] FIG. 11A-FIG. 11D and FIG. 12A-FIG. 12D illustrate a two
particular, alternative embodiments of the embodiment of the
pile-driving apparatus in FIG. 1 alternative to the embodiment in
FIG. 11A-FIG. 11D. FIG. 11A illustrates a toe-drive embodiment
1100, with enlarged views of the sections 1103, 1106, and 1109 in
FIG. 11B-FIG. 11D. Similarly, FIG. 12A illustrates a top-drive
embodiment 1200, with enlarged views of the sections 1203, 1206 in
FIG. 12B and FIG. 12C-FIG. 12D, respectively. Note that both FIG.
12C and FIG. 12D are enlarged views of the section 1206, one a plan
view and the other a partially sectioned view, respectively.
[0055] Turning now to FIG. 11A-FIG. 11D, the section 1103, best
shown in FIG. 11B, contains the gripping device 1112, a part of the
drill string 1115, disposed within the pile 1118, which is a casing
string in this particular embodiment. The umbilical 1121 is also
shown running through the interior 1124 of the pile 1118 and, in
FIG. 11C, to the hammer 1127. FIG. 11B also shows a telescopic
drill pipe section 1130 intermediate the gripping device 112 and
the hammer 1127, and interfacing with the hammer 1127 through an
interface sub 1133. The pile 1118 terminates in a shoe collar 1136
and the embodiment 1100 terminates in a ported shoe 1139 defining
several ports 1142 (only one indicated) through which fluids (not
shown) may pass as described elsewhere.
[0056] Referring now to FIG. 12A-FIG. 12D, the top-drive embodiment
1200 includes a sling 1205 fastened to the wings 1207 of a drill
plate 1206, shown in FIG. 12B, as part of the drill string 1209.
The sling 1205 is also fastened to the pile 1212, which is also a
casing string, to support the weight of the pile 1212, as is shown
in FIG. 12C-FIG. 12D. (To release the pile, the fasteners 1213 can
be explosive bolts that are set off or can be released through the
use of a remotely operated vehicle, not shown.) Note that, in some
alternative embodiments, the hammer 1218 may be coupled to the
drill string 1209 in some other manner, for example, through an
external gripper known as an "elevator" in combination with a
sling. A telescopic drill pipe section 1215 is positioned
intermediate the drill plate 1206 and the hammer 1218, as best
shown in FIG. 12B. The hammer 1218 receives power and control
signals, etc. over the umbilical 1221. The hammer 1218 in top-drive
embodiment 1200 interfaces with the pile 1212 through a chaser sub
1224 and an interface 1227.
[0057] To "rig-up" the pile-driving apparatus 100 in a toe-drive
embodiment, percussive hammer 118 is deployed into the pile 103. In
various alternative embodiments, the rig-up process may also
include positioning one or more transfer subs, filter subs,
flexible hoses, diverter valve assemblies, and at least one joint
of drill pipe. The pile-driving apparatus 100 is racked back into a
derrick 218, shown in FIG. 2. In this particular embodiment, the
pile is a casing string and the casing string is made up, in a
manner well known to those of ordinary skill in the art, starting
with the shoe joint and extending to the desired length. The pile
103 to be driven is then set in a rotary table/drill floor.
[0058] A false rotary table (not shown) is positioned over the pile
103, having been set in the rotary table/drill floor (also not
shown), to support the running of the percussive hammer 118 and any
other desired components down inside of the pile 103. In one
embodiment, the percussive hammer 118 is positioned inside the pile
103. A first stand of drill pipe is added. Although not necessary
for the practice of the present invention, in one embodiment, the
first stand of drill pipe may include a lockable telescoping
section 124 of drill pipe 112. Additional stands of drill pipe may
then be added.
[0059] When the percussive hammer 118 is approximately at the tip
of the shoe joint, a further stand of drill pipe, which includes an
internal gripping device, is added. If so desired, the internal
gripping device may be set by, for example, rotating the drill
string 112. The hammer 118 is landed on the shoe driving ring and
half the stroke of the telescopic section 124 of drill pipe is
compressed. The internal gripping device 115 is then engages and
the pile 103, hammer 118, and drill string 112 is lifted as one
assembly by the drill string 112.
[0060] The pile-driving apparatus 100 is then tripped down to the
sea floor 215, shown in FIG. 2, by adding further stands of drill
pipe. In one embodiment, a grooved bowl and slips may be used as
each stand of drill pipe is added. In one alternative embodiment,
power slips may be used as each stand of drill pipe is added. The
umbilical (not shown) is fed onto the drill string 112 and, in one
embodiment, supported by the quick attach and release clamps 400,
shown in FIG. 4. Once the sea floor 215 has been tagged, and the
pile 103 is substantially in contact with a selected location on
the sea floor 215, self-penetration is logged until the combined
weight of the drill string 112, the pile 103, and the percussive
hammer 118 is supported by the sea floor 215 except for weight
required to keep pile from buckling. The operation of the
percussive hammer 118 then commences to drive the pile 103.
[0061] During the pile-driving process, the percussive hammer 118
uses a prime mover fluid to generate the force, which is
transmitted to the guide shoe tip to excavate a hole. In one
embodiment, the prime mover fluid is hydraulic fluid provided by
the umbilical. The hydraulic fluid may also be retrieved by the
umbilical. In alternative embodiments, pressurized ambient sea
water may be used as the prime mover fluid in the percussive hammer
118. For example, ambient sea water may be provided to the
percussive hammer, which may use the sea water as the prime mover
fluid when operating the percussive hammer in deep water. When
ambient sea water is used as the prime mover fluid, the size of the
umbilical may be reduced. In alternative embodiments, rotation of
the drill string 112 may be used as the prime mover in the
percussive hammer 118.
[0062] Material from the hole created by the pile-driving process
is bailed by returning fluids, such as ambient sea water. In one
embodiment, the returning fluids are discharged through the top of
the casing to the open ocean. In an alternative embodiment, the
material is discharged through a port collar to the sea floor 215.
If the pile tip encounters stiff resistance or sandy layers, fluid
may be dispensed from the tip to reduce external skin friction. In
one embodiment, spent hydraulic fluid, such as the ambient sea
water, may be dispensed. In alternative embodiments, other fluids,
such as the aforementioned lubricants, may be dispensed.
[0063] Upon completion of driving, e.g. when the pile 103 has been
driven to the desired depth, the drill string is rotated to unlock
the internal gripping device 115. In one embodiment, the drill
string 112 may also be rotated to relock the telescoping drill pipe
section 124. The percussive hammer 118 is then withdrawn from the
casing and tripped back to the rotary. Once in the rotary, the
percussive hammer 118 is rigged-down. In one embodiment, rig-down
is the reverse of rig-up.
[0064] In some embodiments, the pile 103 may be driven in stages. A
second pile 103 may, for instance, be run into the rotary and made
up to a desired length. The second pile 103 may have a reduced
diameter and may be internally driven or top-driven. If the second
pile is top-driven, a sacrificial centralizing ring may, in one
embodiment, be included to allow a sleeve to pass the top of a
second stage pile and establish contact with an anvil face.
[0065] More particularly, when the first pile 103 is driven to a
desired depth, the gripping device 115 unset to release the hammer
118, and equipment the drill string 112 tripped back to the rotary,
the hammer 118 is racked back into the derrick 218. A second,
reduced diameter pile 103 is run into the rotary and made up to
required length. Dependent on length and diameter of this second
stage, this pile-driving apparatus 100 may be internally driven or
top-driven. The equipment and procedure for internal driving follow
closely the procedure for the first stage. In the instance of top
driving for the second stage, the pile-driving apparatus 100 is set
up with a sacrificial centralizing ring to allow the sleeve to pass
over the top of the second stage pile and establish contact with
the anvil face. The hammer is then activated and driving proceeds
to desired depth. For internal drives the same procedure for first
stage is followed. Choice of top drive versus internal "toe of
pile" energy application is determined by the prevalent soil
conditions on the location in question. The second stage is landed
on the internal energy transfer ring in the toe joint of the
previously driven section
[0066] By using the present invention, in its various embodiments
and implementations, one or more of a number of advantages may be
realized. For example:
[0067] the hydraulic pressure supplied to the percussive hammer may
be reduced such that the present invention may be used in deep
water pile-driving applications; by driving casing through shallow
water flow sand(s), the underbalanced condition found after
cementing, which may initiate shallow water flow, may be reduced or
prevented;
[0068] friction from the sediment beneath the mud line may be
reduced and the penetration depth of the guide shoe tip
increased;
[0069] in deep water pile-driving, the use of hydraulic oil may be
reduced, or eliminated, which may reduce, or eliminate, the
potential for hydraulic oil to leak or spill into the undersea
environment;
[0070] the size of the umbilical may be reduced, which may reduce
the number of reels used to store and deploy the umbilical, which
may also increase the amount of available deck space on the
platform;
[0071] cutting disposal from drilling may be negated for
environmental and economic advantage; and
[0072] consolidation of the formation may lead to higher pile
foundation capacity and seal flows of gas an fluid that may
otherwise be initiated.
[0073] Still other advantages arising from one or more of the
embodiments and implementations may become apparent to those in the
art having the benefit of this disclosure.
[0074] Moreover, the present invention is expected to enhance prime
equipment utilization by reducing the time required to carry out
installations of caissons or tubular piles into the sea floor 215.
By carrying out some or all of the above described functions "off
the critical path," the invention may accelerate the program of
batch conductor installations in deep water. The invention may also
help overcome certain hostile environments found below the sea
floor 215 in the early stages of the construction of oil wells in
deep water conditions.
[0075] This concludes the detailed description. The particular
embodiments disclosed above are illustrative only, as the invention
may be modified and practiced in different but equivalent manners
apparent to those skilled in the art having the benefit of the
teachings herein. Furthermore, no limitations are intended to the
details of construction or design herein shown, other than as
described in the claims below. It is therefore evident that the
particular embodiments disclosed above may be altered or modified
and all such variations are considered within the scope and spirit
of the invention. Accordingly, the protection sought herein is as
set forth in the claims below.
* * * * *