U.S. patent application number 14/207985 was filed with the patent office on 2014-09-18 for drilling rig for drilling from underground tunnels.
The applicant listed for this patent is Richard Beddoes, Ulric Fournier, Allan Peats, Robert Roulston. Invention is credited to Richard Beddoes, Ulric Fournier, Allan Peats, Robert Roulston.
Application Number | 20140262517 14/207985 |
Document ID | / |
Family ID | 50680133 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140262517 |
Kind Code |
A1 |
Beddoes; Richard ; et
al. |
September 18, 2014 |
DRILLING RIG FOR DRILLING FROM UNDERGROUND TUNNELS
Abstract
A rig for drilling a borehole from an underground tunnel
includes a base assembly, a drilling assembly mounted to the base
assembly, an upper frame assembly mounted to the drilling assembly
above the base assembly, and a support hood coupled to the drilling
assembly and positioned above the upper frame assembly. The support
hood is configured to bear against a ceiling of the tunnel during
drilling operations.
Inventors: |
Beddoes; Richard; (White
Rock, CA) ; Fournier; Ulric; (Sussex, CA) ;
Peats; Allan; (Okotoks, CA) ; Roulston; Robert;
(Victoria, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Beddoes; Richard
Fournier; Ulric
Peats; Allan
Roulston; Robert |
White Rock
Sussex
Okotoks
Victoria |
|
CA
CA
CA
CA |
|
|
Family ID: |
50680133 |
Appl. No.: |
14/207985 |
Filed: |
March 13, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61784199 |
Mar 14, 2013 |
|
|
|
Current U.S.
Class: |
175/52 ; 175/57;
175/94 |
Current CPC
Class: |
E21B 19/08 20130101;
E21B 7/00 20130101; E21C 41/24 20130101; E21B 19/14 20130101; E21B
43/30 20130101; E21B 19/16 20130101; E21B 7/024 20130101 |
Class at
Publication: |
175/52 ; 175/94;
175/57 |
International
Class: |
E21B 7/00 20060101
E21B007/00; E21B 19/16 20060101 E21B019/16 |
Claims
1. A rig for drilling a borehole from an underground tunnel, the
rig comprising: a base assembly; a drilling assembly mounted to the
base assembly; an upper frame assembly mounted to the drilling
assembly above the base assembly; a support hood coupled to the
drilling assembly and positioned above the upper frame assembly,
wherein the support hood is configured to bear against a ceiling of
the tunnel during drilling operations.
2. The rig of claim 1, wherein the base assembly comprises: a
trolley configured to roll along a track; a drilling floor
including a drilling hole configured to pass a drill string; and a
plurality of positioning assemblies mounted to the trolley, wherein
each positioning assembly includes a foot configured to extend
downward into engagement with a floor of the underground
tunnel.
3. The rig of claim 2, wherein the drilling assembly is pivotally
coupled to the base.
4. The rig of claim 2, wherein the base assembly further comprises
a clamping system disposed below the drilling rig floor and
configured to deliver rotational torque to a pipe joint disposed in
the drilling hole.
5. The rig of claim 1, wherein the drilling assembly comprises: a
drilling carriage including a top drive; and an actuator mounted to
the drilling carriage, the support hood, and the base assembly;
wherein the actuator is configured to move the drilling carriage
downward to apply weight-on-bit.
6. The rig of claim 1, wherein the upper frame assembly comprises:
a frame member coupled to the drilling assembly; and a track
assembly coupled to both the frame member and a tunnel track
extending along the underground tunnel; a pipe carriage moveably
coupled to the track assembly, wherein the pipe carriage supports a
plurality of pipe joints.
7. The rig of claim 6, wherein the track assembly is coupled to the
tunnel track with a switch, and wherein the switch is configured to
selectively allow the pipe carriage to enter the track assembly
from the tunnel track.
8. The rig of claim 7, wherein the upper frame assembly further
comprises a toothed gear rotatably coupled to the upper frame
assembly and configured to engage teeth disposed on the pipe
carriage.
9. The rig of claim 1, further comprising a pipe handling assembly
coupled to the drilling rig assembly, wherein the pipe handling
assembly includes a pipe manipulator configured to engage and
rotate a pipe joint.
10. The rig of claim 9, wherein the pipe manipulator comprises: a
housing; a finger pivotally coupled to the housing; a first roller
disposed on the finger; a second roller disposed on the housing;
and a third roller disposed on the finger, adjacent the first
roller; wherein one of the first, second, and third rollers is
configured to be rotated by an actuator.
11. A rig for drilling a borehole from an underground tunnel, the
rig comprising: a base assembly; a drilling assembly mounted to the
base assembly; an upper frame assembly a pipe handling assembly
mounted to the drilling assembly; a track assembly positioned above
the pipe handling assembly, wherein the track assembly is
configured to deliver pipe joints to the pipe handling assembly
during drilling operations.
12. The rig of claim 11, further comprising a support hood coupled
to the drilling assembly, wherein the support hood is configured to
bear against a ceiling of the tunnel during drilling
operations.
13. The rig of claim 11, wherein the base assembly comprises a
base; and wherein the drilling assembly is pivotally coupled to the
base.
14. The rig of claim 12, wherein the drilling assembly comprises: a
drilling carriage; a top drive coupled to the drilling carriage;
and an actuator extending vertically between the support hood and
the base assembly; wherein the actuator is coupled to the drilling
carriage and configured to move the drilling carriage up and
down.
15. The rig of claim 11, wherein the pipe handling assembly
comprises: a pipe manipulator configured to engage a pipe joint
during drilling operations, the pipe manipulator further
comprising: a housing; a finger pivotally coupled to the housing; a
first roller disposed on the finger; a second roller disposed on
the housing; and a third roller disposed on the finger, adjacent
the first roller; wherein one of the first, second, and third
rollers is configured to be rotated by an actuator.
16. The rig of claim 15, wherein the track assembly is coupled to a
tunnel track extending along the underground tunnel; and wherein
the tunnel track and track assembly are each configured to guide a
pipe carriage holding a plurality of pipe joints.
17. The rig of claim 16, wherein the upper frame assembly further
comprises a pipe carriage positioning mechanism disposed adjacent
the track assembly and configured to position a pipe carriage
relative to the pipe handling assembly.
18. A method of drilling a borehole from an underground tunnel, the
method comprising: (a) supplying a plurality of pipe joints to a
drilling rig; (b) gripping a first pipe joint with a pipe handling
assembly; (c) coupling the first pipe joint to a drill string with
the pipe handling assembly; (d) applying a vertical load to the
drill string; and (e) bearing against a ceiling of the tunnel
during (d).
19. The method of claim 18, wherein (a) comprises: carrying the
plurality of pipe joints with a pipe carriage; guiding the pipe
carriage along a track assembly to the drilling rig; and aligning
the pipe joint with the pipe handling assembly.
20. The method of 19, wherein aligning the pipe joint with a pipe
handling assembly comprises engaging teeth disposed on the pipe
carriage with a sprocket rotatably mounted to the drilling rig.
21. The method of claim 18, wherein (b) further comprises extending
a pipe manipulator to engage a pipe joint, the pipe manipulator
comprising: a housing; a finger pivotally coupled to the housing; a
first roller disposed on the finger; a second roller disposed on
the housing; a third roller disposed on the finger, adjacent the
first roller wherein one of the first, second, am third rollers is
configured to be rotated by an actuator.
22. The method of claim 21, wherein (b) comprises engaging the pipe
joint between the first, second, and third rollers.
23. The method of claim 22, further comprising rotating the pipe
joint during (c) with the first, second, or third roller.
24. The method of claim 18, wherein (d) comprises extending a
linear actuator to force a drilling carriage downward.
25. The method of claim 18, further comprising: (e) supporting the
drilling assembly on a base assembly; (f) rotating the drilling
assembly about the base assembly; (g) engaging rollers disposed on
the base assembly with a track disposed within the underground
tunnel.
26. The method of claim 25, further comprising engaging a floor of
the underground tunnel with a foot disposed on the base assembly.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. provisional
application Serial No. 61/784,199, filed Mar. 14, 2013, and
entitled "Drilling Rig for Drilling from Underground Tunnels,"
which is hereby incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND
[0003] Embodiments described herein relate generally to systems and
methods for accessing and producing subsurface hydrocarbons. More
particularly, Embodiments described herein relate to automated
drilling rigs for accessing and producing subsurface hydrocarbons
from an underground tunnel.
[0004] In drilling a borehole into an earthen formation, such as
for the recovery of hydrocarbons or minerals from a subsurface
reservoir, it is conventional to erect a large drilling oil rig at
the surface, connect a drill bit onto the lower end of a "drill
string," and then rotate the drill bit with weight-on-bit (WOB)
applied to drill the borehole along a predetermined path toward the
subsurface reservoir. In general, the bit may be rotated by means
of either a "rotary table" or a "top drive" associated with a
drilling rig and/or a downhole motor incorporated into the
drillstring adjacent to the bit. During the drilling process, a
drilling fluid, also referred to as "drilling mud" or simply "mud,"
is pumped under pressure from the surface down the drill string,
out the face of the drill bit into the borehole bottom, and then
back up to the surface through the annular space ("wellbore
annulus") between the drill string and the borehole sidewall. The
drilling fluid performs several functions such as carrying
formation cuttings to the surface, cooling the drill bit, and
forming a protective cake on the borehole wall (to stabilize and
seal the borehole wall). The drilling fluid returned to the surface
is conditioned by removing the formation cuttings and entrained
gases, and then re-circulated down the drill string.
[0005] Heavy oil deposits in remote locations provide relatively
new and untapped sources of hydrocarbons. However, the harsh
conditions as well as the environmental sensitivity of many such
locations present challenges to conventional surface drilling and
production operations. For example, extreme temperatures over
extended periods of time can be hard on surface equipment and
personnel. In addition, because the relatively large surface
footprint of conventional drilling rigs and associated equipment,
as well as noise generated by such rigs and equipment, may have
negative impacts on sensitive environments, obtaining governmental
approval and drilling permits in many locations can be difficult.
Such governmental approval and permitting issues are further
exasperated by the fact that the recovery of heavy oil deposits
typically requires a relatively high well density, and many state
laws require removal of an existing drilling pad before a new
drilling pad may be put in place. A potential solution to these
challenges is to place a drilling rig below ground. However,
conventional drilling rigs are simply too large to be placed within
an underground or subterranean tunnel while maintaining realistic
costs.
BRIEF SUMMARY OF THE DISCLOSURE
[0006] These and other needs in the art are addressed in one
embodiment by a rig for drilling a borehole from an underground
tunnel. In an embodiment, the rig comprises a base assembly. In
addition, the rig comprises a drilling assembly mounted to the base
assembly. Further, the rig comprises an upper frame assembly
mounted to the drilling assembly above the base assembly. Still
further, the rig comprises a support hood coupled to the drilling
assembly and positioned above the upper frame assembly. The support
hood is configured to bear against a ceiling of the tunnel during
drilling operations.
[0007] These and other needs in the art are addressed in another
embodiment by a rig for drilling a borehole from an underground
tunnel. In an embodiment, the rig comprises a base assembly. In
addition, the rig comprises a drilling assembly mounted to the base
assembly. Further, the rig comprises an upper frame assembly. Still
further, the rig comprises a pipe handling assembly mounted to the
drilling assembly and a track assembly positioned above the pipe
handling assembly. The track assembly is configured to deliver pipe
joints to the pipe handling assembly during drilling
operations.
[0008] These and other needs in the art are addressed in still
another embodiment by a method of drilling a borehole from an
underground tunnel. In an embodiment, the method comprises
supplying a plurality of pipe joints to a drilling rig. In
addition, the method comprises gripping a first pipe joint with a
pipe handling assembly, and coupling the first pipe joint to a
drill string with the pipe handling assembly. Further, the method
comprises applying a vertical load to the drill string. Still
further, the method comprises bearing against a ceiling of the
tunnel while applying the vertical load to the drill string.
[0009] Embodiments described herein comprise a combination of
features and advantages intended to address various shortcomings
associated with certain prior devices, systems, and methods. The
foregoing has outlined rather broadly the features and technical
advantages of the invention in order that the detailed description
of the invention that follows may be better understood. The various
characteristics described above, as well as other features, will be
readily apparent to those skilled in the art upon reading the
following detailed description, and by referring to the
accompanying drawings. It should be appreciated by those skilled in
the art that the conception and the specific embodiments disclosed
may be readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes of the invention. It
should also be realized by those skilled in the art that such
equivalent constructions do not depart from the spirit and scope of
the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a detailed description of the preferred embodiments of
the invention, reference will now be made to the accompanying
drawings in which:
[0011] FIG. 1 is a schematic side view of an embodiment of a
subterranean drilling system including an automated modular
underground drilling rig disposed in a subterranean tunnel in
accordance with the principles disclosed herein;
[0012] FIG. 2 is an enlarged front view of the underground drilling
rig of FIG. 1 disposed within the subterranean tunnel;
[0013] FIG. 3 is a perspective view of the underground drilling rig
of FIG. 1;
[0014] FIG. 4 is a side view of the underground drilling rig of
FIG. 1;
[0015] FIG. 5 is a perspective view of the base assembly of FIG.
1;
[0016] FIG. 6 is a schematic top view of the clamping assembly
mounted to the base assembly of FIG. 5;
[0017] FIG. 7 is a side view of the base assembly and the drilling
assembly of FIG. 1;
[0018] FIG. 8 is a perspective view of the base assembly and the
drilling assembly of FIG. 7;
[0019] FIG. 9 is an enlarged partial front perspective view of the
base assembly and the drilling assembly of FIG. 7;
[0020] FIG. 10 is a perspective view of the upper frame assembly of
FIG. 1;
[0021] FIG. 11 is a cross-sectional view along section 11-11 of
FIG. 4;
[0022] FIG. 12 is a perspective view of an embodiment of a pipe
carriage in accordance with the principles disclosed herein for
delivering drilling pipe joints to the underground drilling rig of
FIG. 1;
[0023] FIG. 13 is a perspective view of the pipe handling assembly
of FIG. 1;
[0024] FIGS. 14-18 are sequential schematic top views of the pipe
carriage of FIG. 12 moving along the track assembly of the
underground drilling rig of FIG. 1 to deliver drilling pipe joints
to the pipe handling assembly of FIG. 13; and
[0025] FIGS. 19-21 are sequential schematic side views illustrating
an embodiment of a method in accordance with the principles
disclosed herein for delivering and installing the underground
drilling rig of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The following discussion is directed to various exemplary
embodiments. However, one skilled in the art will understand that
the examples disclosed herein have broad application, and that the
discussion of any embodiment is meant only to be exemplary of that
embodiment, and not intended to suggest that the scope of the
disclosure, including the claims, is limited to that
embodiment.
[0027] Certain terms are used throughout the following description
and claims to refer to particular features or components. As one
skilled in the art will appreciate, different persons may refer to
the same feature or component by different names. This document
does not intend to distinguish between components or features that
differ in name but not function. The drawing figures are not
necessarily to scale. Certain features and components herein may be
shown exaggerated in scale or in somewhat schematic form and some
details of conventional elements may not be shown in interest of
clarity and conciseness.
[0028] In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to .
. . ." Also, the term "couple" or "couples" is intended to mean
either an indirect or direct connection. Thus, if a first device
couples to a second device, that connection may be through a direct
connection, or through an indirect connection via other devices,
components, and connections. In addition, as used herein, the terms
"axial" and "axially" generally mean along or parallel to a central
axis (e.g., central axis of a body or a port), while the terms
"radial" and "radially" generally mean perpendicular to the central
axis. For instance, an axial distance refers to a distance measured
along or parallel to the central axis, and a radial distance means
a distance measured perpendicular to the central axis. Any
reference to up or down in the description and the claims will be
made for purposes of clarity, with "up," "upper," "upwardly," or
"upstream" meaning toward the surface of the borehole and with
"down," "lower," "downwardly," or "downstream" meaning toward the
terminal end of the borehole, regardless of the borehole
orientation.
[0029] Referring now to FIG. 1, a subterranean or underground
drilling system 10 is shown. In this embodiment, system 10 includes
a first or upper operating tunnel 12 and a second or lower
operating tunnel 14. Each tunnel 12, 14 has a roof or ceiling 12a,
14a, respectively, and a floor 12b, 14b, respectively. A plurality
of laterally spaced, parallel bores or conduits 60 extend
vertically between tunnels 12, 14. Each conduit 60 has a central or
longitudinal axis 65, a first or upper end 60a at floor 12b of
upper tunnel 12, and a second or lower end 60b at ceiling 14a of
lower tunnel 14. Upper ends 60a of each conduit 60 that is not
being used for drilling operations is preferably closed off or
plugged (e.g., with a steel cap) to reduce the risk of equipment or
personnel falling therein. Axes 65, and hence conduits 60, are
vertically oriented and spaced apart a horizontal distance D.sub.60
preferably between 40.0 and 50.0 ft. In addition, each conduit 60
is insulated and has a diameter preferably between 20.0 and 24.0
in.
[0030] An automated modular underground drilling rig 100 is
disposed in upper tunnel 12 over one conduit 60. A blowout
preventer 40 ("BOP 40") is disposed in lower tunnel 14 below rig
100 and the associated conduit 60. A drill string 32 formed from a
plurality of drill pipe sections or joints connected together
end-to-end extends from rig 100, through conduit 60 and BOP 40, and
into the earthen formation 8 below lower operating tunnel 14. A
drill bit is connected to the lower end of drill string 32. Rig 100
applies WOB and rotates the drill bit via drill string 32 to drill
a borehole 30 into formation 8 along a predetermined trajectory.
Rig 100 can also be employed to trip drill string 32 out of
borehole 30 following drilling operations.
[0031] A rail system 20 including a track 21 and one or more cars
22 is provided in each tunnel 12, 14. Each track 21 is disposed on
the floor 12b, 14b of the corresponding tunnel 12, 14, and extends
the entire length of the corresponding tunnel 12, 14. Cars 22 are
moveably disposed on tracks 21 such that they can roll along the
length of tracks 21. Because rail systems 20 are generally disposed
along the floor 12b, 14b of tunnels 12, 14, systems 20 may also be
referred to as a "lower" or "floor" rail systems 20. In addition, a
rail system 80 including a pair of laterally-spaced tracks 81
(note: only one track 81 is visible in FIG. 1) is provided in upper
operating tunnel 12. Tracks 81 are disposed proximate ceiling 12a
and extend along the length of tunnel 12. Because rail system 80 is
generally disposed along ceiling 12a, system 80 may also be
referred to as an "upper" or "ceiling" rail system 80. As will be
described in more detail below, ceiling rail system 80 supports a
plurality of pipe carriages 180 that move along tracks 81 to
deliver drill pipe joints to rig 100 during drilling operations and
take drill pipe joints from rig 100 during tripping operations. In
this embodiment, rail systems 20, 80 are automated to minimize
human intervention in drilling and tripping operations. For
example, rail systems 20, 80 can be electrically powered, and
monitored and controlled in tunnels 12, 14 from a remote
location.
[0032] Referring now to FIGS. 2-4, automated modular underground
drilling rig 100 is shown. Rig 100 has a central axis 105
substantially aligned with axis 65 during drilling and tripping
operations, and includes a base assembly 120, a drilling assembly
140 mounted to base assembly 120, an upper frame assembly 160
positioned atop drilling assembly 140, a bearing or support hood
220 supported by upper frame assembly 160, and a pipe handling
assembly 190 positioned adjacent the drilling assembly 140. As will
be described in more detail below, bearing hood 220 is braced
against ceiling 12a of tunnel 12 during drilling operations. Base
assembly 120, drilling assembly 140, frame assembly 160, hood 220,
and pipe handling assembly 190 will each be described in turn.
[0033] Referring now to FIG. 5, base assembly 120 is shown. Base
assembly 120 generally supports rig 100 along floor 12b. In this
embodiment, base assembly 120 includes a base or trolley 126, a rig
floor 124 pivotally coupled to trolley 126, a plurality of
positioning assemblies 130 positioned about the perimeter of
trolley 126, and a clamping system 114 mounted to rig floor 124.
Trolley 126 is generally rectangular in shape and has a first or
front end 126a, a second or rear end 126b, and lateral sides 126c,
126d extending between ends 126a, 126b. A vertical central axis 125
is oriented perpendicular to trolley 126 and extends through the
center of trolley 126. Each end 126a, 126b of trolley 126 is
provided with a pair of wheels or rollers 122 and a coupling 133 to
facilitate the movement of rig 100 through tunnel 12 along rail
system 20. In particular, rollers 122 are positioned to roll along
track 21 of upper tunnel 12 and couplings 133 provide robust
connection points at which base assembly 120 can be pushed or
pulled along track 21.
[0034] Rig floor 124 is pivotally coupled to trolley 126 with a
pair of hinges 137 extending therebetween proximal rear end 126b.
Thus, floor 124 can rotate relative to trolley 126 about a
horizontal axis extending between hinges 137. As will be described
in more detail below, rotation of floor 124 allows rig 100 to
traverse through portions of tunnel 12 having a vertical height
less than the overall height of rig 100 when fully assembled and
erected as shown in FIG. 3. Rig floor 124 includes a cover plate
127 having a central drilling hole 129 and a plurality of mounting
apertures 123 disposed about central aperture 129. As will be
described in more detail below, drilling hole 129 provides a path
for pipe joints and drill string 32 to be run into and out of
conduit 60 and borehole 30 during drilling and tripping operations,
and drilling assembly 140 is mounted to base assembly 120 via
mounting holes 123.
[0035] A positioning assembly 130 is disposed at each corner of
rectangular trolley 126 and function to secure and maintain the
position of base assembly 120 and drilling rig 100 within tunnel 12
during drilling and tripping operations. In this embodiment, each
positioning assembly 130 includes an actuator 132, a housing 134
rigidly mounted to trolley 126, a screw jack 138 extending downward
from housing 134, and a foot 136 mounted to the lower end of screw
jack 138. Actuator 132 extends from housing 134 and is coupled to
screw jack 138. In particular, actuator 132 rotates screw jack 138
to vertically raise and lower foot 136 relative to housing 134,
trolley 126 and tunnel floor 12b. To secure trolley 126 and rig 100
in position during drilling and tripping operations, screw jacks
138 are extended downward until feet 136 engage tunnel floor 12b
and lift rollers 122 from track 21. To enable movement of trolley
126 and rig 100 along track 21, screw jacks 138 are lifted upward
until rollers 122 engage track 21 and feet 136 disengage floor
12b.
[0036] Referring now to FIGS. 5 and 6, clamping system 114 is
attached to drilling rig floor 124 below plate 127 and is generally
disposed about drilling hole 129. In this embodiment, clamping
system 114 has a vertical central axis 115 coaxially aligned with
axis 125 of trolley 126, an upper clamp assembly 116 and a lower
clamp assembly 118 positioned immediately below upper clamp
assembly 116. Upper clamp assembly 116 includes a pair of radially
opposed clamping members 116a, 116b configured to be moved radially
inward and outward relative to axis 115, and lower clamp assembly
118 includes a pair of radially opposed clamping members 118a, 118b
configured to be moved radially inward and outward relative to axis
115. In addition, upper clamp assembly 116 can pivot or rotate
about axis 115 relative to lower clamp assembly 118. In general,
during threaded joint makeup operations (i.e., during drilling
operations), lower clamp assembly 118 grips the uphole end of
drillstring 32 while a new pipe joint is threaded into the uphole
end to increase the length of drillstring 32. To sufficiently
tighten and pre-load the threaded connection between the
drillstring 32 and the new pipe joint, lower clamp assembly 118
continues to grip the uphole end and prevent its rotation while
upper clamp assembly 116 moves into engagement with lower end of
the new pipe joint, grips, and applies rotational torque to the new
pipe joint. Conversely, during threaded joint breaking operations
(during tripping operations), lower clamp assembly 118 grips
drillstring 32 immediately below the threaded connection between
two pipe joints in drill string 32 to be broken and prevents
rotation of drill string 32 below that connection while upper clamp
assembly 116 moves into engagement with drill string 32 immediately
above the connection, grips and applies rotational torque to break
the connection between assemblies 116, 118. Examples of clamp
assemblies that can be used for clamp assembly 114 are disclosed in
U.S. patent application Ser. No. 61/783,859, which is hereby
incorporated herein by reference in its entirety.
[0037] Referring now to FIGS. 7-9, drilling assembly 140 is shown
mounted to base assembly 120. Drilling assembly 140 provides
rotational torque to drill string 32 and WOB during drilling
operations to drill borehole 30. In this embodiment, drilling
assembly 140 includes a first pair of vertical support posts 142, a
second pair of vertical support posts 148, a plurality of diagonal
support members 144, a pair of linear actuators 146, and a drilling
carriage 150. Each post 142 is oriented parallel to axis 105, and
has a first or upper end 142a secured to upper frame assembly 160,
and a second or lower end 142b secured within one hole 123 in
drilling floor 124 (see also FIG. 5). Similarly, each post 148 is
oriented parallel to axis 105, and has a first or upper end 148a
secured to upper frame assembly 160 and a second or lower end 148b
secured to drilling floor 124. Each support member 144 has a first
or upper end 144a pinned to upper frame assembly 160 with a
connection pin 149a and a second or lower end 144b pinned to
trolley 126 with a connection pin 143. In this embodiment, two
support members 144 extend upward from lateral side 126c of trolley
126 (see also FIG. 5) and taper towards each other to form a truss
support, while the other two members 144 extend upward from lateral
side 126d of trolley 126 and taper towards each other to form a
truss support.
[0038] Referring still to FIGS. 7-9, each linear actuator 146 is
oriented parallel to axis 105 and has a first or upper end 146a, a
second or lower end 146b, a post section 146c extending axially
from the upper end 146a, and a sleeve section 146d disposed about
the post section 146c. Sleeve section 146d extends axially up and
down relative to the corresponding post section 146d. Upper ends
146a are secured to upper frame assembly 160 and lower ends 146b
are secured within holes 123 in drilling floor 124 (see also FIG.
5).
[0039] Drilling carriage 150 includes a body 152 and a top drive
154 mounted to body 152. Body 152 is provided with a first pair of
through bores 158 extending axially therethrough and a second pair
of through bores 156 extending axially therethrough. Support posts
142 are slidingly received within the first pair of bores 158, and
sleeve sections 146d are secured within the second pair of bores
156. Thus, as actuators 146 move sleeve sections 146d axially up
and down, body 152 is translated axially up and down and is guided
by posts 142. Top drive 154 is configured to receive an upper end
of a drill pipe joint (a single joint or joint disposed at the
upper end of drill string 32) and rotate the drill pipe joint about
axis 105, thereby facilitating the makeup or breakup of threaded
joints or rotating the drill bit at the lower end of string 32.
[0040] Referring now to FIGS. 10 and 11, upper frame assembly 160
is shown. Upper frame assembly 160 functions as an upper support
and bracing structure for the modular underground drilling rig 100
and serves to interconnect tracks 81 with rig 100. In this
embodiment, upper frame assembly 160 has a central axis 165 and
includes a frame member or plate 162 and a pipe carriage track
assembly 170 coupled to the plate 162. Frame assembly 160 is
symmetric about axis 165, which is oriented perpendicular to and
intersects axis 105. Plate 162 has a first or front end 162a, a
second or rear end 162b, and lateral sides 162c, 162d disposed on
opposite sides of axis 165. In addition, plate 162 includes a front
section 167 extending from end 162a and a rear section 163
extending from section 167 to rear end 162b. Front section 167
includes a first pair of vertical through bores 164 and a second
pair of vertical through bores 166. Upper ends 142a of posts 142
are secured within bores 164 and upper ends 146a of actuators 146
are secured within bores 166 (see also FIG. 8). In particular,
upper end 146a of each linear actuator 146 extends through one hole
166 and is secured therein with a tie head 147 that extends axially
upward from front section 167.
[0041] Upper frame assembly 160 further includes a plurality of
screw jacks 169. In this embodiment, a total of three screw jacks
are included--two screw jacks 169 disposed on the front section 167
on opposing sides of the axis 165 and one screw jack 169 disposed
on the rear section 163 substantially along the axis 165. Each of
the screw jacks 169 are coupled to a motor 169a, which is
configured to force each screw jack 169 to rotate, thereby either
extending or retracting each screw jack 169 axially with respect to
the axis 105. As is best shown in FIG. 2, screw jacks 169 are
coupled to the hood 220, which is braced against the ceiling 12a of
a tunnel 12. As will be described in more detail below, screw jacks
169 allow for enhanced adjustability of the height of hood 220
within a subterranean tunnel (e.g., tunnel 12) in addition to the
screw jacks 138 disposed on trolley 126 of base assembly 120,
previously described. Further, as will also be described in more
detail below, screw jacks 169 transfer reactive forces from the
drill bit, through drill string 32 and rig 100 to ceiling 12a of
tunnel 12 via hood 220 to rigidly brace rig 100 during drilling
operations.
[0042] Referring again to FIGS. 10 and 11, a central through bore
168 extends axially through section 167 of plate 162 and is
coaxially aligned with the axis 105. Bore 168 is sized and
positioned to receive top drive 154 when carriage 150 is disposed
in its uppermost position (see also FIG. 9). Rear section 163
includes a pair of apertures or holes 161. Upper ends 148a of
support posts 148 are secured within holes 161 (see also FIG.
8).
[0043] A pipe carriage positioning mechanism 177 is mounted to rear
section 163 and includes a gear or toothed sprocket 179 positioned
on the underside of plate 162 and a motor (not shown) to rotate
sprocket 179 about a vertical axis 177a. As will be described in
more detail below, sprocket 179 engages mating teeth 183 provided
on an upper frame member 184 of a pipe carriage 180 to: (a)
position the carriage 180 such that a pipe joint 34 carried by
carriage 180 can be supplied to pipe handling assembly 190 during
drilling operations, and (b) position the carriage 180 such that a
pipe joint 34 removed from drill string 32 can be placed on
carriage 180 with pipe handling assembly 190 during tripping
operations.
[0044] Referring still to FIGS. 10 and 11, track assembly 170
facilitates the movement of carriages 180 to and from rig 100. In
this embodiment, track assembly 170 includes an arcuate rail or
track 172 and a pair of switches 174 coupled to track 172. Track
172 has a generally semi-circular section 171 with ends 171a, 171b,
and a pair of S-shaped transition sections 173; one transitions
section 173 extends from each end 171a, 171b. Section 171 is
centered on axis 165 in bottom view (FIG. 11) and extends around
positioning mechanism 177. Each transition section 173 has a first
end 173a coupled to one switch 174 and a second end 173b contiguous
with a corresponding end 171a, 171b of section 171.
[0045] As best shown in FIG. 10, each switch 174 includes a
rectangular housing 175 and a track selector sled 176 moveably
disposed within housing 175. Housing 175 has a first or laterally
outer end 175a, a second or laterally inner end 175b, and two
support members 175c extending between the ends 175a, b. Ends 175a,
175b are referred to herein as an "outer" and "inner" because they
are arranged distal and proximal axis 165, respectively. Sled 176
supports a straight track section 176a and an arcuate track section
176b. Sled 176 is moved laterally inward and outward between ends
175a, 175b to position either track section 176a or track section
176b into alignment with a corresponding track 81 of ceiling track
system 80 (see also FIG. 1). As will be described in more detail
below, when track section 176a is aligned with a corresponding
track 81, carriages 180 cannot be transferred between tracks 81,
172; however, when track section 176b is aligned with a
corresponding track 81, carriages 180 can be transferred between
tracks 81, 172. In general, any suitable mechanism known in the art
can be used to move sled 176 relative to housing 175 including,
without limitation, a hydraulic actuator, an electric motor, etc.
The movement of sled 176 to selectively align track sections 176a,
176b with track 81 is preferably automated to minimize human
intervention.
[0046] Referring now to FIGS. 11 and 12, pipe carriage 180 is
shown. As previously described, pipe carriages 180 move along
tracks 81 to deliver drill pipe joints 34 to rig 100 during
drilling operations and take drill pipe joints from rig 100 during
tripping operations (see also FIG. 1). Each carriage 180 supports a
plurality of elongate cylindrical pipe joints 34 in vertical
orientations. Pipe joints 34 are added to drill string 32 to
lengthen drill string 32 during drilling operations, and removed
from drill string 32 to shorten drill string 32 during tripping
operations. Each pipe joint 34 has a first or upper end 34a
comprising an internally threaded box end, a second or lower end
34b comprising an externally threaded pin end, a cylindrical outer
surface 34c extending between ends 34a, 34b, and a throughbore 34d
extending between the ends 34a, 34b.
[0047] Each pipe carriage 180 includes a frame 182 and a pair of
supports 187 extending upward from frame 182. Frame 182 has a
vertical central axis 185, a first or upper end 182a, and a second
or lower end 182b. An arc-shaped horizontal frame member 184 is
disposed at upper end 182a, an arc-shaped horizontal frame member
186 disposed at lower end 182b, and a pair of elongate supports 188
extending vertically between members 184, 186.
[0048] Upper frame member 184 has a uniform radius of curvature
equal to the radius of curvature of semi-circular section 171 and
includes a plurality of circumferentially-spaced teeth 183 along
its radially inner concave side and a plurality of
circumferentially-spaced receptacles 189 along its radially outer
convex side. Each receptacle 189 is sized and shaped to mate and
engage one pipe joint 34 proximal its upper end 34a. As is best
shown in FIG. 11, teeth 183 are sized to mate and engage with
sprocket 179. Members 187 extend axially upward from upper frame
member 184. The upper end of each member 187 is coupled to track
81, 172 by a roller or other means that allows carriage 180 to be
controllably moved thereon.
[0049] Referring still to FIGS. 11 and 12, lower frame member 186
is oriented parallel to upper frame member 184 and also has a
uniform radius of curvature equal to the radius of curvature of
semi-circular section 171. In addition, lower frame member 186
includes a plurality of circumferentially-spaced cylindrical
recesses 181 extending axially from the top surface of frame member
186. Each recess 181 in lower frame member 186 is substantially
coaxially aligned with one receptacle 189 of upper frame member
184. As is best shown in FIG. 12, each recess 181 is sized and
shaped to receive lower end 34b of one pipe joint 34 seated in a
corresponding receptacle 189.
[0050] Referring now to FIGS. 4 and 13, pipe handling assembly 190
is shown. Pipe handling assembly 190 transfers pipe joints 34
between carriage 180 and rig 100, as well as initiates the
threading/unthreading of pipe joints 34 to the upper end of drill
string 32 during drilling/tripping operations, respectively. In
this embodiment, pipe handling assembly 190 includes a pipe
manipulator 192 and a mounting assembly 200 coupling manipulator
192 to posts 148. Manipulator 192 includes a body or housing 194
and a pipe handling arm 196 extending from housing 194. Arm 196 is
extended and retracted from housing 194 with an actuator 198
mounted to housing 194. In general, actuator 198 can be any
suitable device for extending and retracting arm 196 including,
without limitation, an electric motor, a hydraulic motor, or the
like.
[0051] Housing 194 has a horizontal central axis 195, a first end
194a, a second end 194b, and a receptacle 194c extending axially
from end 194b. First end 194a is positioned proximal central axis
105 of rig 100 and second end 194b is positioned distal axis 105,
and thus, ends 194a, 194b may be referred to herein as "inner" and
"outer", respectively, relative to axis 105.
[0052] Arm 196 includes an elongate body 199 extending from housing
194 and a curved claw or finger 191 moveably coupled to end 199a of
body 199 distal housing 194. In particular, curved finger 191 has a
first end 191a pivotally coupled to end 199a and a second end 191b
opposite end 191 a. Finger 191 generally extends across end 199a of
body 199, thereby defining a bay or receptacle 193 therebetween. As
will be described in more detail below, finger 191 is configured to
pivot about end 191a to grasp and release drill pipe joints 34, as
well as accommodate drill pipe joints 34 having different outer
diameters. As best shown in FIG. 13, a vertical roller 197a is
rotatably mounted to end 191b of finger 191 and another vertical
roller 197b is rotatably mounted to end 199a of body 199 generally
opposite roller 197a. Further, in this embodiment, a third roller
197c is rotatably mounted to finger 191, between the ends 191a, b
and adjacent the roller 197a (note: the roller 197c is shown in
FIG. 13 with hidden lines). In this embodiment, rotation of roller
197b is powered with an actuator 201 mounted to body 199, however,
rollers 197a, 197c are not driven and are free to rotate in either
direction. As will be described in more detail below, a pipe joint
34 is received within receptacle 193 and engaged by rollers 197a,
197b, 197c. Roller 197b is then rotated with actuator 201 to rotate
pipe joint 34 disposed between rollers 197a, 197b, 197c to
thread/unthread a threaded connection between the pipe joint 34 and
the drillstring 32. In general, actuator 201 can be any suitable
device for rotating roller 197b including, without limitation, an
electric motor, a hydraulic motor, or the like.
[0053] Referring still to FIG. 13, mounting assembly 200 moveably
couples pipe manipulator 192 to posts 148. Mounting assembly 200
includes a pair of guide collars 202 mounted to housing 194 and
disposed about posts 148. Collars 202 slidingly engage posts 148 as
mounting assembly 200, and hence pipe manipulator 192 moves
vertically up and down along posts 148. Such vertical movement of
pipe manipulator 192 is controlled by an actuator 212 coupled to
housing 194. In particular, actuator 212 rotates an externally
threaded vertical shaft 208 coupled to rig floor 124 with a support
post 210. Shaft 208 threadably engages a ball nut 214 disposed on
post 210, and thus, as shaft 208 is rotated in one direction,
mounting assembly 200 and pipe manipulator 194 move upward along
posts 148, and as shaft 208 is rotated in the opposite direction,
mounting assembly mounting assembly 200 and pipe manipulator 194
move downward along posts 148. In general, actuator 212 can
comprise any suitable device for rotating shaft 208 including,
without limitation, a hydraulic actuator, an electric motor,
etc.
[0054] Referring now to FIGS. 1, 8, and 13, during drilling
operations, carriages 180 deliver pipe joints 34 to rig 100 (see
also FIG. 1); pipe handling assembly 190 removes a joint 34 from
carriage 180, positions the joint 34 in line with the upper end of
drill string 32, and threads the lower end of the pipe joint 34
into drill string 32. Clamping system 114 then completes the makeup
and preloading of the threaded connections between pipe joint 34
and drill string 32 as previously described. In this embodiment,
top drive 154 engages the upper end of lengthened drill string
(i.e., the upper end of pipe joint 34 added to the drill string 32)
either before or after actuation of clamping system 114. Once
clamping system 114 has been released from pipe joint 34, top drive
154 rotates drill string 32 while applying WOB to advance the drill
bit at the lower end of drill string 32 along a predetermined
trajectory. This process is repeated with additional pipe joints 34
to drill borehole 30. It should be appreciated that this process is
performed in reverse to trip drill string 32 out of borehole
30.
[0055] Pipe joints 34 are delivered to rig 100 using carriages 180,
tracks 81, and track assembly 170. In FIGS. 14 and 15, carriage 180
is shown bypassing rig 100; in FIGS. 16 and 17, carriage 180 is
shown delivering pipe joints 34 to drilling rig 100; and in FIG.
18, carriage 180 is shown being positioned along track assembly 170
with sprocket 179 to align one pipe joint 34 with pipe handling
assembly 190. In general, pipe joints 34 are loaded on carriage
180, and carriage 180 moves along track 81 in tunnel 12 toward rig
100. At rig 100, the position of switch 174 determines whether
carriage 180 is directed to rig 100 or bypasses rig 100. As shown
in FIGS. 14 and 15, with switch 174 positioned to align the
straight track sections 176a with tracks 81, carriage 180 continues
along track 81 and passes track assembly 170, thereby bypassing rig
100. However, as shown in FIGS. 16 and 17, with switch 174
positioned to align curved track section 176b with track 81,
carriage 180 is directed onto track assembly 170. As shown in FIG.
18, carriage 180 continues along track assembly 170 until sprocket
179 of rig 100 engages teeth 183 of carriage 180, thereby allowing
sprocket 179 to fine tune the position of carriage 180 to align
pipe joints 34 (one at a time) with pipe handling assembly 190.
[0056] Referring now to FIGS. 1, 4, 5, 8, 11, 12, and 13, sprocket
179 aligns one pipe joint 34 with pipe handling assembly 190. Next,
actuator 198 actuates to extend arm 199 and finger 191 is actuated
to open receptacle 193 to receive the aligned pipe joint 34
therein. With pipe joint 34 sufficiently disposed in receptacle
193, finger 191 is actuated to grasp the pipe joint 34 with rollers
197a, 197c. Actuator 198 then continues to extend arm 199 to align
the pipe joint 34 with drilling hole 129 in rig floor 124. Next,
roller 197b is rotated to drive the rotation of the drill pipe
joint 34 about axis 105 and pipe handling assembly 190 is lowered
with actuator 212 to initiate the threading of the lower end 34b of
the pipe joint 34 into the upper end of drill string 32. Clamping
assembly 114 completes the makeup, thereby incorporating pipe joint
34 into drill string 32. Drilling carriage 150 is then lowered
until top drive 154 engages upper end 34a of the pipe joint 34.
Next, top drive 154 drives the rotation of pipe joint 34 as
actuators 146 urge carriage 150 downward, thereby applying WOB and
rotating the drill bit with drill string 32 to lengthen borehole
30. As linear actuators 146 urge carriage 150, drill string 32, and
the drill bit downward, upward reactive forces are transferred to
the surrounding formation by engagement of hood 220 and ceiling 12a
of tunnel 12 to effectively braces rig 100 within tunnel 12.
[0057] In general, the time and associated cost for forming
underground tunnels is directly related to the size of the tunnels
(e.g., diameter, height and width, etc.). Accordingly, in some
cases it may be desirable to transport rig 100 to the drilling
location in a tunnel having a height less than the fully assembled
rig 100. For example, FIGS. 19-21 illustrate the transport of rig
100 to a drilling site through a portion of tunnel 12 having a
height less than the assembled height of rig 100, and the
subsequent installation rig 100 at the drilling site. Referring
first to FIG. 19, rig floor 124 is pivoted via hinges 137 away from
trolley 126, thereby rotating upper frame assembly 160 towards the
floor 12b and decreasing the overall height of rig 100. This
enables rig 100 to pass through sections of tunnel 12 having a
height less than the height of the fully deployed rig 100. During
transport through tunnel 12, feet 136 are raised from floor 12b and
wheels 122 roll along tracks 21.
[0058] Referring now to FIGS. 20 and 21, at the drilling location
along tunnel 12, drill rig floor 124 is rotated about the hinges
137 onto trolley 126 resulting in upper frame assembly 160 being
rotated to a vertical, deployed position. It should be appreciated
that a cut out or recess 13 is provided along ceiling 12a at the
drill site to provide sufficient space for upper frame assembly 160
to be rotated to a vertical position. In addition, feet 136 are
lowered into engagement with floor 12b and base assembly 120 is
lifted upward to disengage wheels 122 from tracks 21. Next,
drilling assembly 140, support hood 220, and track assembly 170 are
coupled to upper frame assembly 160 and the pipe handling assembly
190 is coupled to posts 148. The vertical spacing between hood 220
and ceiling 12a may then be adjusted until hood 220 contacts and
engages ceiling 12a, thereby effectively bracing rig 100 within
tunnel 12.
[0059] In the manner described, embodiments of modular drilling rig
100 can be used to drill a borehole from a subterranean tunnel. By
drilling from a tunnel (e.g., tunnel 12) as opposed to
above-ground, personnel and equipment are protected from harsh
weather conditions at the surface, and the footprint of drilling
operations at the surface is significantly decreased. In addition,
rig 100 is preferably fully automated to minimize human
intervention and associated risk in underground operations. For
example, actions such as the delivery of pipe joints 34, the makeup
and/or break up of connections between pipe joints 34 and drill
string 32, the application of WOB by carriage 150, and application
of rotational torque by top drive 154 are all preferably automated
processes that are monitored and controlled by a remote control
system.
[0060] Although embodiments described and disclosed herein have
included a pair of linear actuators 146 within drilling assembly
140, it should be appreciated that more or less than two linear
actuators 146 may be used while still complying with the principles
disclosed herein. Additionally, while embodiments described and
disclosed have included a total of four positioning assemblies 130
mounted to trolley 126, it should be appreciated that in other
embodiments, more or less than four positioning assemblies may be
included while still complying with the principles disclosed
herein. Further, it should be appreciated that in other
embodiments, either the roller 197a, and/or the roller 197b on
manipulator 192 may be driven to the rotate in order to also rotate
a pipe joint 34 disposed within the receptacle 193 while still
complying with the principles disclosed herein. Still further,
while embodiments described and disclosed herein have included a
total of three upper screw jacks 169, in other embodiments, the
number and arrangement of screw jacks 169 may be varied while still
complying with the principles disclosed herein. Also, in other
embodiment, no screw jacks 169 may be included and the tie heads
147 may directly couple to the hood 220, in order to brace rig 100
against the ceiling 12a of tunnel 12 during drilling
operations.
[0061] While preferred embodiments have been shown and described,
modifications thereof can be made by one skilled in the art without
departing from the scope or teachings herein. The embodiments
described herein are exemplary only and are not limiting. Many
variations and modifications of the systems, apparatus, and
processes described herein are possible and are within the scope of
the invention. For example, the relative dimensions of various
parts, the materials from which the various parts are made, and
other parameters can be varied. Accordingly, the scope of
protection is not limited to the embodiments described herein, but
is only limited by the claims that follow, the scope of which shall
include all equivalents of the subject matter of the claims. Unless
expressly stated otherwise, the steps in a method claim may be
performed in any order. The recitation of identifiers such as (a),
(b), (c) or (1), (2), (3) before steps in a method claim are not
intended to and do not specify a particular order to the steps, but
rather are used to simplify subsequent reference to such steps.
* * * * *