U.S. patent application number 13/192547 was filed with the patent office on 2011-11-17 for automatic control system for connecting a dual-member pipe.
This patent application is currently assigned to The Charles Machine Works, Inc.. Invention is credited to Geoff D. Koch, Bradley E. Mitchell.
Application Number | 20110278065 13/192547 |
Document ID | / |
Family ID | 39675197 |
Filed Date | 2011-11-17 |
United States Patent
Application |
20110278065 |
Kind Code |
A1 |
Mitchell; Bradley E. ; et
al. |
November 17, 2011 |
Automatic Control System For Connecting A Dual-Member Pipe
Abstract
A system and method of making up and breaking out a dual-member
drill string. The system comprises a spindle, a spindle carriage
and a drive frame. The drive frame provides thrust to the spindle,
while the spindle carriage provides rotation. The spindle has an
outer spindle and an inner spindle, and is adapted to connect to a
pipe section having an outer pipe section and an inner pipe
section. Inner joints are geometrically shaped, while outer joints
are threaded. When making up dual member drill string, the spindle
is advanced, with the outer spindle rotating, and the inner spindle
rotating in alternating directions, or "dithering." A float sensor
and a processor are used in tandem to cooperatively couple the
inner spindle with the inner pipe sections and the outer spindle
with the outer pipe sections.
Inventors: |
Mitchell; Bradley E.;
(Perry, OK) ; Koch; Geoff D.; (Perry, OK) |
Assignee: |
The Charles Machine Works,
Inc.
Perry
OK
|
Family ID: |
39675197 |
Appl. No.: |
13/192547 |
Filed: |
July 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12632326 |
Dec 7, 2009 |
7987924 |
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13192547 |
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11828963 |
Jul 26, 2007 |
7628226 |
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12632326 |
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60820371 |
Jul 26, 2006 |
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Current U.S.
Class: |
175/27 |
Current CPC
Class: |
E21B 7/046 20130101;
E21B 19/165 20130101 |
Class at
Publication: |
175/27 |
International
Class: |
E21B 44/00 20060101
E21B044/00 |
Claims
1. A drill string make-up system comprising: a drive frame; a
spindle comprising an inner spindle and an outer spindle
connectable to a pipe section having an inner pipe section and an
outer pipe section; a means for providing thrust and rotation to
both the inner spindle and outer spindle, wherein the inner spindle
is rotatable independent of rotation of the outer spindle; and a
processor to automatically control rotation of the inner spindle
180 degrees in alternating clockwise and counterclockwise
directions.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. Ser. No.
12/632,326 filed on Dec. 7, 2009, which is a continuation of U.S.
Ser. No. 11/828,963 filed on Jul. 26, 2007, which claims the
benefit of provisional patent application Ser. No. 60/820,371 filed
on Jul. 26, 2006, the entire contents of which are incorporated
herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of horizontal
boring machines, and more particularly to a makeup/breakout system
for dual-member pipes.
SUMMARY OF THE INVENTION
[0003] In one embodiment the present invention is directed to a
method for coupling a carriage to a dual-pipe drill pipe section.
The method comprises the steps of advancing the carriage having an
inner spindle and an outer spindle, automatically rotating the
inner spindle clockwise and counterclockwise in an alternating
fashion, and detecting a carriage float position. The inner spindle
and the outer spindle of the carriage are connectable to a pipe
section having an inner pipe section and an outer pipe section. The
detected carriage float position indicates the inner spindle has
not coupled with the inner pipe section.
[0004] Another embodiment of the present invention is directed to a
method for adding a pipe section to a drill string. The pipe
section comprises an inner pipe section and an outer pipe section.
The drill string comprises an inner pipe and an outer pipe. The
method comprises the steps of attaching a pipe section to a
carriage, aligning an end of the inner pipe section with an end of
the inner pipe, advancing the pipe section such that the inner pipe
section is coupled to the inner pipe, monitoring a carriage float
position, detecting a carriage float position, and coordinating
rotation and thrust of the outer pipe section. The carriage is
adapted to advance and rotate the pipe section, and characterized
by an amount of float. The inner pipe and inner pipe section's ends
are aligned such that the inner pipe section may be coupled to the
inner pipe. The detected carriage float position is indicative of
the inner pipe section not being coupled to the inner pipe. Thrust
and rotation of the outer pipe section are coordinated such that
the outer pipe section and the outer pipe are threaded
together.
[0005] Yet another embodiment of the present invention is directed
to a drill string make-up system. The system comprises a spindle, a
carriage, a float sensor, and a processor. The spindle comprises an
inner spindle and an outer spindle. The carriage is adapted to
provide thrust and rotation to the spindles. The inner spindle is
rotatable independent of the rotation of the outer spindle. The
float sensor is adapted to determine the amount of float in the
carriage and to transmit a float signal. The processor is adapted
to receive the float signal and to control the rotation of the
inner spindle in alternating clockwise and counterclockwise
directions in response to the float signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a view of a boring machine comprising the
makeup/breakout system of the present invention.
[0007] FIG. 2 is a cut-away view of a makeup/breakout system.
[0008] FIG. 3 is a side view of a spindle carriage.
[0009] FIG. 4 is a flowchart depicting a method of connecting a
spindle to a pipe section.
[0010] FIG. 5 is a flowchart depicting a method of coupling an
inner spindle.
[0011] FIG. 6 is a flowchart depicting a method of coupling an
outer spindle.
DETAILED DESCRIPTION OF THE DRAWINGS
[0012] The present invention is directed to an automatic dual-pipe
makeup/breakout system and a method for using the same. The system
is provided for connecting or disconnecting an existing dual-pipe
drill string to an additional dual-pipe section. Dual member pipes
are useful in conjunction with horizontal boring machines
particularly in rocky conditions. With a dual member pipe, an outer
pipe is used for steering the drill string, while an independently
rotatable inner member is used to provide cutting force for a drill
bit. A preferred embodiment for a dual-member drill string system
is disclosed in U.S. Reissue Pat. No. RE38,418, the contents of
which are incorporated herein by reference. A system and method for
the automatic connection of a one-pipe drill string to a one-pipe
spindle is given in U.S. Pat. No. 7,011,166, the contents of which
are also incorporated herein by reference.
[0013] Turning to the drawings in general and FIG. 1 in particular,
there is shown in FIG. 1 a makeup/breakout system, designated by
reference number 10 in accordance with the present invention for
use with a horizontal boring machine 11. The makeup/breakout system
10 is generally secured to a drill frame 12 of a boring machine.
The makeup/breakout system 10 is operated and monitored with
controls located at an operator's console 13. The operator's
console 13 contains a control panel having a display, joystick, and
other machine function control mechanisms, such as switches and
buttons. From the control panel, each of the underlying functions
of the boring machine 11 can be controlled. The display on the
control panel may include a digital screen and a plurality of
signaling devices, such as gauges, lights, and audible devices, to
communicate the status of the operations to the operator. A
processor 14 is adapted to respond to signals from various sensors
of the system 10 and adjust functions of the system in response to
the signals. The system 10 further comprises a pipe handling system
15 supported on the drill frame 12 for placement of sections of
pipe for the operations described below.
[0014] Turning now to FIG. 2, the system 10 generally comprises a
drive frame 16, a spindle carriage 17 supported on the drive frame
and a spindle 18. The system 10 comprises a front clamp wrench 19,
shown in FIG. 1, and pipe loader grippers (not shown). The front
clamp wrench 19 is located at a front end of the drill frame 12 and
adapted to prevent rotation or translation of a dual member drill
string 22. The pipe loader grippers are located on the pipe
handling system 15 and adapted to prevent rotation or translation
of a pipe section 24.
[0015] With reference again to FIG. 2, the drive frame 16 is
adapted to provide power to the spindle carriage 17. The spindle
carriage 17 is supported on the drive frame 16 and adapted to
support and provide rotation and thrust to the spindle 18. As used
herein, thrust is intended to mean the advancement or retraction of
the carriage 17. Preferably, the spindle carriage 17 is connected
to the drive frame 16 by a spring-centering device 26. The
spring-centering device 26 biases the spindle carriage 17 to a
default position relative to the drive frame 16.
[0016] As depicted in FIG. 2, the system 10 is connected to the
dual-member drill string 22 by way of the spindle 18. The
dual-member drill string 22 is made up of a plurality of pipe
sections 24. Each pipe section 24 comprises an inner pipe section
30 and an outer pipe section 32. Preferably, each outer pipe
section 32 has threaded male and female ends for threaded
connecting to other pipe sections. Preferably, each inner pipe
section 30 has geometrically formed male and female ends for torque
transmitting slip fit connection to other inner pipe sections. As
those skilled in the art will appreciate, alternatives to the
threaded connections of the outer pipe sections 32 and the
geometrical connections of the inner pipe sections 30 are
contemplated.
[0017] The spindle 18 comprises an inner spindle 34 and an outer
spindle 36. The outer spindle 36 preferably comprises a threaded
spindle pipe joint 38. The inner spindle 34 preferably comprises a
geometrical spindle pipe joint 40. The threaded spindle pipe joint
38 is adapted for connection to a threaded pipe joint 42 on a first
end of the outer pipe section 32. The geometrical spindle pipe
joint 40 is adapted for connection to a geometrical pipe joint 44
on a first end of an inner pipe section 30. Preferably, the
geometrical pipe joints 40, 44 comprise hex joints. As used herein,
a pipe joint can be either of the male or female ends of a pipe
section 24.
[0018] The processor 14 is adapted to receive signals from a float
sensor 60 and a rotation pressure sensor 61. The processor 14
receives and interprets the signals, and automatically adjusts
thrust and rotation of the spindle 18 as will be discussed further
below.
[0019] The float sensor 60 is used to measure the relative amount
of float between the spindle carriage 17 and the drive frame 16.
Preferably, the float sensor 60 is an electromagnetic absolute
position sensor, though other devices could also be used, such as
linear variable displacement transducers, photoelectric devices,
resistive potentiometers, and ultrasonic sensors. In the embodiment
illustrated in FIG. 3, the float sensor 60 comprises a sensor rod
62, a magnet 64, and associated electronics 66. The sensor rod 62
is secured to the drive frame 16. The magnet 64 is coupled to the
spindle carriage 17. The magnet 64 is positioned to move along the
sensor rod 62 as the carriage 17 floats relative to the drive frame
16. The associated electronics 66 are adapted to determine the
position of the magnet 64 along a length of the sensor rod 62 and
transmit a float signal indicative of the amount of relative float.
Position sensors such as this are common in the art and many
alternative sensors may be contemplated for use with the present
invention.
[0020] With reference generally to FIG. 4, shown therein is a
preferred procedure for connecting the spindle 18 to a pipe section
24. The routine begins at 300 and is equally applicable to the
system 10 in a drilling or a backreaming mode. At 302, a check is
made to see if the spindle 18 is in a rear of the drill frame 12,
the front clamp wrench 19 is closed, and the drilling machine is
operating in the drilling mode. If the machine is operating in the
drilling mode, acting in parallel, the processor 14 will have begun
a routine to activate the pipe handling assembly 20 to load a pipe
section 24. At 304, a check is made to see if the pipe section 24
is in position for adding. If so, connection of the spindle 18 to a
pipe section 24 may begin. If the answer was no at 302, the routine
checks at 306 to see if the spindle 18 is at a front of the drill
frame 12, the front clamp wrench 19 is closed, and if the drilling
machine is in the backreaming mode. If so, connection of the
spindle 16 to the drill string 22 may begin.
[0021] At 308, the rotation and thrust of the spindle 18 is begun
as a connection routine is started. The connection routine is
described below in FIG. 6. It will be appreciated that thrust of
the carriage 17 and rotation of the spindle 18 should be
coordinated by the processor 14. If the carriage 17 is applying too
much thrust or too little thrust, the carriage 17 will displace
from the default position relative to the drive frame 16. The float
sensor 60 signals this displacement, and the processor 14
automatically adjusts the thrust and/or rotation so the float
sensor 60 will move back to the default position. If the float
sensor 60 reaches a limit, or is significantly displaced while
rotation is not occurring (thus keeping the spindle 18 from
coupling with a pipe section 24), a limit signal is sent to the
processor 14 and thrust and/or rotation are automatically
stopped.
[0022] In the drilling mode, the pipe handling system 15 will place
a pipe section 24 comprising an inner pipe section 30 and an outer
pipe section 32 into a position proximate the spindle 18. The pipe
holders of the pipe handling system 15 grip and hold the pipe
section 24 in place. One of skill in the art will appreciate the
pipe handling system 15 can position the pipe section 24 and
prevent some rotation of the pipe section as the spindle 18 is
connected.
[0023] While the carriage 17 is advanced and the outer spindle 36
rotates, the dithering of the inner spindle 34 is begun at 310. The
dithering process is more fully described below in regards to FIG.
5. "Dithering" comprises the alternate rotating of the inner
spindle 34 in a clockwise and counterclockwise fashion.
[0024] Dithering is needed because the geometrical spindle pipe
joint 40 of the inner spindle 34 may contact the geometrical pipe
joint 44 of the inner pipe section 30 if the joints are not
geometrically aligned to permit coupling of the joints. This
contact displaces the spindle carriage 17 from the drive frame 16
as the carriage advances, causing the float sensor 60 to become
displaced from the default position. When an orientation of the
geometrical pipe joint 44 of the inner pipe section 30 matches an
orientation of the geometrical pipe joint 40 of the inner spindle
34, the inner spindle and the inner pipe section will couple.
[0025] When dithering, the clockwise and counterclockwise rotation
amount of the inner spindle is kept approximately the same using a
sensor which provides inner spindle 34 rotation travel information.
Preferably, the inner spindle 34 is rotated through a 180 degree
arc to achieve coupling. After each rotation, the travel of the
spindle is read and compared to a target travel. If the actual
inner spindle 34 travel is not equal to the desired travel, a
correction can be made to the inner spindle on a next movement. If
the float sensor 60 detects that the float position reaches a limit
at 312, a speed or an orientation of the inner spindle 34 may be
alternatively adjusted, an inner spindle rotation direction
changed, and dither restarted at 314. Preferably, the angle of
inner spindle 34 rotations may be adjusted to geometrically align
the joints. Alternatively, an operator may override the automated
process and match the orientation of the inner spindle 34 to the
orientation of the inner pipe section 30. When the inner spindle 34
begins to couple with the inner pipe section 30, the spring
centering device 26 will force the spindle carriage 17 to a default
float position.
[0026] In the preferred embodiment, the outer spindle 36 does not
contact the outer pipe section 32 until the inner spindle 34
couples with the inner pipe section 30. When the inner spindle 34
aligns with the inner pipe section 30, the spring centering device
26 pushes the spindle carriage 17 back to a default float position,
which further couples the inner spindle to the inner pipe section.
Preferably, the threaded joint 42 of the outer pipe section 32 will
begin to couple with the threaded pipe joint 38 of the outer
spindle 36 as the inner spindle 34 is coupled. One skilled in the
art will appreciate that improper coupling of a threaded joint on a
pipe section may cause the locking or stripping of the threads.
[0027] In order to avoid stress on the threads, rotation and thrust
of the spindle 18 is coordinated by the float sensor 60 and the
processor 14 to ensure proper coupling. If the spindle 18 is
rotating it is assumed by the processor 14 that the spindle is
being threaded to or from the pipe section 24. The processor 14
synchronizes the thrust speed with the rotation to keep the float
in its default position. If the drive frame 16 gets too far ahead
of the spindle 18 mechanism, the float position will be off center
at 316, and thrust is stopped at 318 until rotation catches up and
the spindle carriage 17 moves back toward the center position.
Likewise, if the spindle carriage 17 gets too far ahead of the
drive frame 16 at 316, rotation will be slowed or stopped at 318
until thrust catches up with the drive frame and re-centers
float.
[0028] The system further comprises the rotation pressure sensor 61
as an additional way of checking whether connections are properly
made up. When the outer spindle 36 is coupling with the outer pipe
section 32, the sensor will detect substantially constant rotation
pressure. When the coupling is complete, the rotation of the outer
spindle 36 continues, and the rotation pressure may spike. The
processor 14 detects the rise in the rotation pressure sensor
signal and determines that the coupling is complete. The processor
14 then may stop the rotation of the spindle carriage 17.
Preferably, the pipe joints are adapted such that when threads on
the outer pipe section 32 are fully made up the sliding geometrical
pipe joints 40, 44 are fully seated.
[0029] If in drilling mode, the rotation pressure sensor will not
sense completed connection until the pipe section 24 is connected
to the drill string 22. Rotation and thrust of the spindle 16 are
continued as the pipe section 24 is advanced towards the drill
string 22. To connect the pipe section 24 to the drill string 22,
the front clamp wrench 19 is closed about the drill string. The
first pipe section 24, coupled to the spindle 18, is then advanced,
and the inner pipe section 30 is dithered. Preferably, the inner
pipe section 30 must be coupled to the inner pipe section of the
drill string 22 before the outer pipe section 32 contacts the outer
pipe section of the drill string. The float sensor 60 and the
rotation pressure sensor detect at 320 when coupling of the pipe
section 24 and the drill string 22 is complete and rotation and
thrust are stopped at 322.
[0030] Upon coupling the pipe section 24 to the drill string 22,
the front clamp wrench 19 opens and the pipe grippers of the pipe
handling system 15 are retracted to allow drilling operations to
resume at 324. Rotation and thrust of the spindle 18 cause the
drill string 22 to advance, until such time as the spindle carriage
17 reaches a front end of the drill frame 12 and the process of
adding another pipe section 24 is repeated.
[0031] The flow chart of FIG. 5 depicts an example of logic used by
the processor 14 during the dithering of the inner spindle 34. The
routine waits at 402 for a signal that the spindle 18 is in a
dither zone 404. The dither zone is defined as the position of the
spindle carriage 17 either at the rear of the drill frame 12 when
the spindle 18 is to be connected to a pipe section 24 or at the
front of the drill frame when the spindle is to be connected to the
drill string. If the spindle 18 is in the dither zone at 404, the
routine asks if the wrench is closed at 406. At 408, the routine
asks if outer spindle 36 rotation is clockwise. If not, a check is
made at 410 to see if thrust is forward. If thrust is forward at
410, or if outer spindle 36 rotation is clockwise at 408, then the
inner spindle 34 is rotated at 416.
[0032] The routine waits for a given time to allow the rotation of
the inner spindle 34 to expire at 418. When the time is expired at
418, the processor 14 checks the dither angle at 420. An incorrect
dither adjustment will require the processor 14 to calculate the
dither adjustment at 422 and adjust the dither speed at 424.
Finally, the direction of rotation of the inner spindle 34 is
reversed at 426. The makeup/breakout process can proceed at
428.
[0033] A logic sequence for the processor 14 to follow for
coordinating thrust and rotation of a threaded outer spindle 36 and
outer pipe section 32 during pipe makeup/breakout is shown in FIG.
6. The processor 14 begins at 502. The processor 14 checks that the
spindle 18 is in a float zone at 504 and that the front clamp
wrench 19 is closed at 506. With these conditions met, a request
for rotation is read at 508. If a request for rotation is present
at 510, the rotation speed of the outer spindle 36 is limited at
512, an output for thrust based on rotation is calculated at 514 by
the processor 14, and a float position is read at 516. If a request
for rotation is not present at 510, a request for thrust is read at
518. If a request for thrust is present at 520, thrust speed is
limited at 522 and the float position is read at 516. If float is
not centered at 524, and float is not at a limit at 526, thrust
adjustment is calculated at 528, thrust speed is adjusted at 530,
and the makeup/breakout process may continue at 532. If the float
is at a limit at 526, thrust or rotation is stopped as needed at
534, and the makeup/breakout process continues at 532. If no thrust
request is present at 520, thrust and rotation of the outer spindle
36, if any, is stopped at 536 and the makeup/breakout process may
continue at 532.
[0034] Various modifications can be made in the design and
operation of the present invention without departing from its
spirit. For example, the inner pipe may be threaded or connect in a
snap-together or lock together manner. Other configurations of the
outer pipe are also applicable. Measurements other than float, such
as contact, proximity, pressure, force or torque can be utilized
for controlled coordination of the dual-pipe drill string. Thus,
while the principal preferred construction and modes of operation
of the invention have been explained in what is now considered to
represent its best embodiments, it should be understood that within
the scope of the appended claims, the invention may be practiced
otherwise than as specifically illustrated and described.
* * * * *