Patent Publication Number: US-7584810-B1

Title: Top drive power swivel assembly

Description:
FIELD 
     The present embodiments relate to machinery and methods for exploring beneath the earth&#39;s surface and, more particularly, to stratigraphic exploration. 
     BACKGROUND 
     A need exists for methods and machinery useful on a drilling rig that allows drilling through consolidated surfaces that can be accomplished quickly, efficiently, economically and with as little disruption as possible at a field site. 
     A further need exists for a top drive power swivel assembly that mates to a travelling frame for forming an integrated travelling frame swivel assembly that is more secure, more stable than currently available power swivels that do not mate to the frame. 
     The present embodiments meet these needs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description will be better understood in conjunction with the accompanying drawings as follows: 
         FIG. 1  is a front view of the top drive power swivel assembly mated to a travelling frame using a connector embodiment of the invention. 
         FIG. 2  is a perspective view of the components of the top drive power swivel assembly. 
         FIG. 3  is a side view of an embodiment of the top drive power swivel assembly mated to the travelling frame without connectors on a tower which is depicted as a derrick. 
         FIG. 4  is a detailed front view of an embodiment of the top drive power swivel assembly with connectors. 
         FIG. 5  is an exploded view of an embodiment of the top drive power swivel assembly attached to a travelling frame. 
         FIG. 6  is a bottom perspective view of a top drive power swivel assembly. 
     
    
    
     The present embodiments are detailed below with reference to the listed Figures. 
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Before explaining the present apparatus in detail, it is to be understood that the apparatus is not limited to the particular embodiments and that it can be practiced or carried out in various ways. 
     The present embodiments relate to a top drive power swivel assembly for a drilling rig, such as mobile drilling rig for drilling for natural gas, oil, or water. 
     The invention provides a top drive power swivel assembly accommodating the needs listed above for use with a structurally moveable tower or derrick, having a drilling rig mast. 
     Another benefit of an embodiment of the invention is that it provides a means for attaching the power swivel to the traveling frame assembly that is mechanically stabilized by upper and lower attachment points. 
     The inventive top drive power swivel assembly has a travelling frame for moving along at least two tubulars which are part of a tower. The tubulars can be legs of a tower or a derrick. The tubulars can be a set of rails installed on the legs of a derrick, such as a set of steel rails welded to the front of the derrick 
     The travelling frame has at least two lower travelling frame extensions, a first and second lower travelling frame extensions and two upper travelling frame extensions, at least a first and second upper travelling frame extensions. In an embodiment, 4 upper travelling frame extensions can be contemplated for use, one at each corner of the travelling frame nearest the top drive power swivel. The lower travelling frame extensions can be contemplated to having a triangular shape with rounded edges and an opening or eye in the portion of the extension furthest from the travelling frame. These triangular in shape extensions are contemplated to be mounted horizontally to the axis used by the travelling frame for moving up and down the derrick. This means, that the extensions point towards the top drive power swivel in this embodiment. 
     The top drive power swivel can have a housing for holding the top drive power swivel components. 
     The housing has at least two upper housing extensions and in an embodiment, at least four upper housing extensions. Additionally, the housing has at least two lower housing extensions, and in the embodiment shown in  FIG. 6  at least four lower housing extensions. 
     Each extension has an opening. The openings can be round or ellipsoidal, as long as the opening can accommodate a connector. The openings have a diameter from about 1 inch to about 6 inches. The connector can be a pin, the pin can be a solid steel rod. The pin can extend across the housing to engage at least two housing extensions disposed in parallel with at least two travelling frame extensions. 
     A first connector can be used to penetrate at least one of the openings in an upper travelling frame extension and at least one opening in an upper housing extension simultaneously, thereby securely engaging the travelling frame to the housing with the extensions. It is contemplated that the extensions can be welded or otherwise fastened to each component. 
     A second connector can be used to penetrate at least one opening in a lower travelling frame extension and at last one opening in a lower housing extension, again simultaneously. Simultaneously, in this application, means both extensions are held together at the same time using the connector to securely engage the travelling frame to the housing. 
     A top drive power swivel is mounted to the housing. The top drive power swivel includes a rotating drive shaft rotatable on an axis. The power swivel receives power from at least two hydraulic motors. The rotating drive shaft rotates between about 0 revolutions per minute to about 150 revolutions per minute. 
     A pair of sheave assemblies are mounted to the travelling frame. Each sheave assembly engages a hoisting means which can include pulleys, blocks, and wire rope or cable. 
     Two guide wheel assemblies are connected to the travelling frame. Each guide wheel assembly is disposed on sides of the travelling frame opposite each other. The guide wheel assembly is contemplated to be constructed from at least one wheel, and possibly 3 or more wheels, up to 10 wheels depending on the size of the travelling frame between a pair of wear pads. For any one guide wheel assembly, 3 guide wheels might be placed between two wear pads enabling the travelling frame to roll up and down the tubulars, such as on rails that communicate with the guide wheels or with tubular portions of a derrick directly. 
     Now the invention will be further described with reference to the Figures. 
       FIG. 1  depicts a front view of drilling equipment being used in the field. The specific details of the derrick and its mounting base (e.g., truck mounted, track-mounted vehicle, etc.). 
     Within the derrick  15  which can be a tower in another embodiment, there is a travelling frame  12  that engages tubulars  14  and  16  respectively by fitting onto rails, which are not shown, which are mounted to the tubulars or by fitting directly onto the tubulars. 
     The tubulars can be round, ellipsoid or square tubulars. The rails can be channel steel. 
     The travelling frame  12  has a housing  11 . The travelling frame supports at least two sheave assemblies  50  and  52  that each engage a hoist means  103  and  105 . The hoist means enable the top drive power swivel assembly to be raised and lowered substantially vertically. 
     At least two top travelling frame extensions and two bottom travelling frame extensions are non removably secured to the travelling frame closest to the top drive power swivel. The extensions can be welded, adhered, or otherwise fastened to the travelling frame.  FIG. 1  shows an embodiment with four bottom travelling frame extensions, although in this front view, only two are shown as elements  20  and  22 . Similarly, this embodiment has four top travelling frame extensions, although again, in this view only two are shown as elements  24  and  26 . 
     The top drive power swivel  28  is secured within the travelling frame  12 . The top drive power swivel  28  is attached enabling ease of drilling through many layers quicker than conventional drilling equipment. 
     Within the field of drilling, in general, a power swivel is a mechanical device that simultaneously suspends the weight of a drill string and provides for the rotation of the drill string beneath it. A power swivel includes a stationary part, that is coupled with a power source in this instance, two hydraulic motors and a rotating part that is coupled with a drill string. A power swivel permits a high-volume flow of drilling mud or air from the stationary part through to the rotating part without leaking. 
     A hydraulic motor powers the top drive power swivel  28 . Shown in  FIG. 6 , a first and second hydraulic motor,  38  and  39  respectively operate the power swivel. 
     The hydraulic motors cause a drive shaft of the power swivel to rotate which is secured to a drill string. By rotating the drill string a drill bit rotates and cuts through the strata. Typical size bore holes would range from about 1.25 inches in diameter to about 6.25 inches in diameter; although larger scale equipment can be used to produce larger holes. 
     Conventionally, the power swivels have been secured to various devices at midpoints for use in drilling. This midpoint connection is insecure, unstable and fraught with issues of balance. 
     Returning to  FIG. 1 , the top drive power swivel  28  is securely mounted to the travelling frame using a plurality of connectors. In this front view, connectors  30  and  32  engage bottom extensions  20  and  22  respectively for the bottom extensions and connectors  33  and  34  engage top extensions  24  and  26  respectively. 
     The connectors can be pins, such as solid steel rods, or coated steel rods or lubricated rods which insert into eyes or openings formed in each of the extensions. 
     The connectors can be round or cylindrical, and can range in diameter between about 2 inches to about 6 inches. The connectors can range in length between about 5 inches to about 6 feet. The connectors can be made from hollow steel. The connectors can be coated at least partially or encapsulated such as with Teflon™ or a polyamide, like Nylon 6,6 to insure an easy fit and reduce rust. Alternatively, the connectors can be simply lubricated with an oil, like a white oil which is environmentally biodegradable for ease of insertion. 
     In another embodiment, one pin can engage a plurality of extensions, such as one connector like connector  30  can extend the entire width of the top drive power swivel and engage two sets of bottom extensions by passing through more than one extension via each opening. That is, several extensions can be lined up in parallel and one connector can secure all the extensions together. 
     It is contemplated that at least two, and maybe four or more extensions can be used to hold the top drive to the travelling frame on a top side or a bottom side. It is contemplated that different numbers of extensions and connectors can be used between the top side and the bottom side and between a left portion of a top drive power swivel and a right portion of a top drive power swivel. 
     The extensions can be welded or fastened to each component, the top drive power swivel or the travelling frame with bolts, adhesive, riveting, or clamps. It is contemplated to be within the scope of the invention to have different fastening schemes for each unit, for example one extension may be welded to the travelling frame while extensions to the top drive power swivel may be bolted. 
     Similarly, there are at least two, or more top drive extensions welded or fastened with bolts, adhesive, riveting or clamps to the top drive. 
     As depicted in  FIG. 1 , a first bottom top drive extension  40  extends vertically down from the top drive to be engaged by the pin  30 . Similarly a second bottom top drive extension  42  extends vertically downward from the top drive to be engaged by pin  32 . Two top drive extensions, which are not shown, extend upwardly from the top drive to be engaged by the connectors  33  and  34  respectively, which in this embodiment are pins. 
     Also in  FIG. 1  the dead line  5  and the fast line  4  are depicted and can be used in hoisting the top drive power swivel assembly. 
       FIG. 2  shows another embodiment of components of the power swivel top drive assembly  28 . These components include a first sheave assembly  50  and a second sheave assembly  52  but more sheave assemblies can be used. 
       FIG. 2  depicts a sheave assembly for each side of the top drive power swivel  28 . The sheave assemblies are held to the top drive by sheave pins,  54   a  and  54   b.    
     Guide wheel assemblies  100  and  101 , are secured to each side of the travelling frame  12 . 
     Interior of the guide wheel assemblies are at least one guide wheel.  FIG. 2  depicts three guide wheels for each set of the guide wheel assemblies. Notably for guide wheel assembly  101 , guide wheels  64 ,  66 , and  68  are depicted. It is contemplated that between 1 guide wheel and up to 10 guide wheels can be used with the invention. 
     The guide wheels are held between wear pads. For guide wheel assembly  101 , wear pad  58  is on one side of the wheels and wear pad  60  is located on the other side of the wheels. The wheels are positioned back from the wear pads, keeping the wheels in a crevice, or canyon, enabling the travelling frame to slide securely against the rails or tubulars. 
     Each wheel is affixed between the wear pads using wheel shafts,  70 ,  72 , and  74  respectively. 
     It should be noted that the top drive power swivel  28  of this embodiment causes the rotating drive shaft  29  to move vertically along an axis  71 . Additionally the top drive power swivel  28  is connected to the travelling frame  12  by the third connector for the top extensions  76  and a fourth connector for the top extensions  37 . 
     The top drive power swivel has all normal major working components, such as a motor, shaft, brake assembly, bearing assembly and gooseneck fastened to the travelling frame. This top drive unit enables several lengths of standard pipe to be assembled above ground in a short drill rig. 
       FIG. 3  depicts the top drive power swivel assembly  28  on the derrick  15  secured to the hoist means  103  in a side view showing tubular  14 . 
       FIG. 4  is a detailed front view of the top drive power swivel assembly secured with eight extensions secured to the top drive, eight extensions secured to the travelling frame using eight pins to hold the two units together in an interlocking, interleaved manner. In this front detailed view only four pins can be seen. Pins  30 ,  32 ,  33  and  34  support the travelling frame extensions  20 ,  22 ,  24  and  26  to top drive extensions  40 ,  42 ,  43  and  45  respectively. 
       FIG. 5  is a detailed exploded view of the top drive power swivel. In this figure, the power swivel is shown detached from the travelling frame which is a stiff rigid assembly made of steel that rolls on the rollers along the tubulars. 
     In  FIG. 5 , the openings in the extensions can be viewed. Notably are the eyes or openings for the top extensions of the top drive power swivel, namely  51   a ,  51   b , and  51   c . Four extensions are presented in this embodiment, only three can be seen in this view. 
     The top extensions of the travelling frame depict openings  51   d ,  51   e  and  51   f.    
     Embodiments of the pins usable as connectors are also shown as connectors  130 ,  132 ,  133 ,  134  and  135 . The top drive power swivel housing  11  is easy to discern in the Figure. The two hydraulic motors  38  and  39  are also shown in this embodiment. 
       FIG. 6  shows a bottom perspective view of the top drive power swivel assembly with the two hydraulic motors  38  and  39  the lower housing extensions  40 ,  42 ,  43  and  45 . The lower travelling frame extensions  20  and  21  are depicted as well. 
     In an embodiment, the first and second lower travelling frame extensions extend generally horizontally to the axis. Additionally, the first and second lower housing extensions can extend generally parallel to the axis. 
     In another embodiment, the first and second upper travelling frame extensions extend generally parallel to the axis. The top drive power swivel assembly can have the first and second upper housing extensions extend generally parallel to the axis. The top drive power swivel assembly can have at least one of the connectors is a pin. 
     The various embodiments of the swivel described herein relate to fluid drilling. The present invention can utilize water, or mud, drilling techniques as well. Similarly, air drilling, mist drilling, foam drilling and other drilling techniques are contemplated for use with the present invention. 
     Although the present invention has been described and illustrated in detail, it is understood that the same is by way of illustration and example only, and is not to be taken as a limitation, in scope or spirit, of the present invention which is limited only by the terms of the appended claims.