Abstract:
An hydraulic top drive apparatus and tubular handling device mounted beneath a conventional crown block, traveling block, bail, and swivel, and including an hydraulically powered top drive pipe rotating device having a single hollow shaft with threads at each end for mating on one end with the drill string or tubular to be worked and on the other with a drilling swivel. The top drive rotating device is attached to a wheeled support frame which moves on guide rails which are mounted to a derrick. The top drive apparatus can be pivoted in a horizontal plane away from the vertical axis of the drill string or other tubulars. Motive force is applied directly to the drill string or other tubular being worked. A pivotable pipe lifting and positioning device is mounted beneath the top drive on the wheeled support frame for picking up pipe and positioning it so that the pipe threads can mate precisely with the threads of the top drive shaft. A makeup/breakout wrenching device is pivotably connected to the wheeled support frame beneath the top drive.

Description:
This application is a continuation of application Ser. No. 657,302, filed Oct. 3, 1984, now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to top drive well drilling and operation apparatus and tubular handling apparatus related thereto. 
     2. Description of the Prior Art 
     It has previously been common in well drilling and other well operations to impart motive force to the drill string or other tubular members being worked with by means of the old rotary table drive apparatus or electric motor top drives. The old rotary drive tables are inefficient and costly. The electric top drives have had numerous problems; for example, to move and support drill strings weighing up to 500 tons, the Direct Current traction motors used in electric top drives must be very large, consequently they require a large and effective motor cooling system. Also all of the safety problems associated with electricity are considerations when using an electric top drive. Because of these shortcomings, obtaining compliance with accepted safety codes and insurance certification for the use of electric top drives has been a tedious, expensive, and time-consuming process. There are also numerous structural/functional disadvantages associated with the use of electric top drives; for example, one prior art electric top drive utilizes an expensive thrust bearing to support the drill string rather than using the shaft of the motor itself. Another prior art electric top drive has an electric motor which is offset from the shaft supporting the drill string which results in an imbalance in the distribution of the reactive torque applied. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an hydraulic top drive apparatus and tubular handling device that overcomes the problems associated with the prior art drives. Mounted beneath a conventional crown block, traveling block, bail, and swivel, the present invention includes an hydraulically powered top drive pipe rotating device having a single hollow shaft with threads at each end for mating on one end with the drill string or tubular to be worked and on the other with a drilling swivel. The top drive rotating device is attached to a wheeled support frame which moves on guide rails which are mounted to a derrick. The mounting of the top drive apparatus permits it to be pivoted in a horizontal plane away from the vertical axis of the drill string or other tubulars. Motive force is applied directly to the drill string or other tubular being worked. Also, the top drive is fully reversible so that motive force can be applied in either direction. A makeup/breakout wrenching device is pivotably connected to the wheeled support frame beneath the top drive. A pipe lifting and positioning device is mounted beneath the top drive on the wheeled support frame for picking up pipe and positioning it so that the pipe threads can mate precisely with the threads of the top drive shaft. 
     It is, therefore, an object of the present invention to provide an efficient and safe hydraulic top drive for use in well operations. 
     Another object of the present invention is the provision of such a top drive which imparts a concentric and balanced motive force to the tubular to be worked. 
     Yet another object of the present invention is the provision of means for pivoting the top drive apparatus in a horizontal plane away from the drill string or other tubulars being worked without having to tilt the top drive from the vertical. 
     A further object of the present invention is the provision of such a top drive apparatus in which its shaft itself supports the drill string so that no thrust bearing support is required. 
     Another object of the present invention is the provision of such a top drive apparatus in combination with a pipe lifting and positioning device, both of which are mounted on a wheeled support which in turn is mounted on rails connected to the derrick for moving the top drive apparatus and pipe positioning device up and down within the derrick. 
     Yet another object of the present invention is the provision of such a top drive in which the pipe positioning device can be pivoted in a horizontal plane away from the drill string or other tubular being worked without having to tilt it from the vertical. 
     A further object of the present invention is the provision of such an hydraulic top drive apparatus in which full rated torque output can be achieved within safe operating limits. 
     Another object of the present invention is the provision of a device for precisely positioning drill pipe. 
     Yet another object of the present invention is the provision of an hydraulic top drive apparatus which permits the lifting of the drill bit off the bottom of the hole when making connections of pieces of the drill string. 
     Still another object is the provisions of such a top drive with which drill pipe connections may be broken at any elevation in the derrick and which provides smooth rotary torque at any elevation. 
     Another object of the present invention is the provision of such a top drive which can be utilized for all normal drilling, reaming and casing operations, can be used to drill with single or multiple sections of pipe, and can ream in ninety-foot increments. 
     Yet another object of the present invention is the provision of an hydraulic top drive apparatus which can be used to connect tubular members without using spinning chains. 
     A further object of the present invention is the provision of such a top drive that has a rise and fall counterbalance system. 
    
    
     Other and further objects, features and advantages of this new top drive apparatus and pipe positioning device will be apparent from the following description of the presently preferred embodiments of the invention, given for the purpose of disclosure and taken in conjunction with the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view of a derrick showing an hydraulic top drive according to the present invention, 
     FIG. 2A is a top view of the device of FIG. 2B, 
     FIG. 2B is a side view of the pipe positioning and handling mechanism, 
     FIG. 3 is a sectional view of the bail link counterbalance, 
     FIG. 4 is a sectional view of the splined quick disconnect, 
     FIG. 4A is a view along line 4A--4A of FIG. 4, 
     FIG. 5 is a top view partially in section of a pivotable breakout/makeup wrenching device assembly, 
     FIG. 6 is a side view of the assembly of FIG. 5, 
     FIG. 6A is an enlarged view of a portion of FIG. 6, 
     FIG. 7 is a bottom view partially in section of the lower section of the assembly of FIG. 6, 
     FIG. 8 is a sectional view of the assembly of FIG. 7, and 
     FIG. 9 is a sectional view of the power clamping apparatus of the assembly of FIG. 6. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIG. 1, an hydraulically powered drilling top drive apparatus 10 according to the present invention is suspended from a commercially available swivel 11 fitted with optional bail links 12 for counterbalancing. This swivel in turn is attached to a traveling block 13 which is attached by cables to a crown block 14 in the derrick 15. The top drive 10 is attached to a wheeled support frame 16 which is mounted upon guide rails 17 which are mounted to the derrick 15. The attachment of the drilling top drive 10 to the swivel 11 shaft may be made through a one piece threaded hollow shaft or by using a splined quick disconnect 18. The hydraulic fluid which operates the top drive 10 is conducted through pipes 19 and hoses 20 from a power unit 21 located at a convenient point. The top drive 10 has a hollow shaft with a threaded top end 30a for connection to the swivel 11. 
     The drilling top drive 10 is attached to the wheeled support frame 16 in such a manner that it may be rotated in a horizontal plane about pivots 22 on the wheeled support frames 16 for maintenance or removing from service. The drill pipe positioning arm 23 is also pivoted from the support frame 16 in such a manner that it may be rotated in a horizontal plane to a drill pipe pick-up point using cylinders 24. The positioning arm may then be rotated to a point which positions the drill pipe 66 directly over the centerline of the well being drilled. Additional cylinders 25 then elevate the drill pipe 66 to allow a screwed connection to be made to either: the threaded bottom end of the top drive shaft 30, the threaded bottom end of the elevator link adapter 27 (when it is used), or to the threaded end of the saver sub 67 when it is used. Since the motive force of the top drive is centered about the central shaft 30, the reactive forces are balanced and a concentric balanced force is imparted to the drill string. 
     The wrenching device 26, 31 is also pivotably connected on the support frame 16 in such a manner that it may be rotated aside in a horizontal plane to allow access for maintenance or removal. 
     Referring now to FIG. 2, the positioning arm bowl 33 is designed with a &#34;U&#34; shaped opening with a tapered seat to match the drill pipe tool joint. The latch arm 35 moves to allow the entry of drill pipe. The latch arm is spring loaded to the closed position. Drill pipe may be loaded by pushing into the opening 35a. A cylinder 36 is used to move the latch to the open position. Cylinder 25 when actuated, moves the drill pipe into contact with the mating thread on the top drive shaft 30. The latch may also be activated manually. 
     Referring now to FIG. 3, the hydraulically cushioned bail link has a piston 34 which acts upward in the cylinder barrel 36 as a result of fluid under pressure entering the interior of the barrel 36. This internal force acts like a compression spring. When the rod 34 is actuated downward by a load the potential energy is stored within the chamber 38. As long as the load is more than the potential energy, the distance between the attaching holes 43a and 43b will be at maximum. When the load is next reduced such as when a section of drill stem is unscrewed, the distance between the attaching holes will decrease, the drill string proper will remain stationary in the hole, the drilling swivel 11 will move upward as the threaded members of the drill string separate, while the section being unscrewed is raised by the action of the piston 34 within the barrel 36 to an upward position. When the load is entirely removed, the distance between the centers of the attaching holes will be at minimum. Packing seals 37 maintain the pressure required to move the piston. 
     Referring now to FIG. 4, a tubular member 40 containing a male spline and an extension bearing a sealing element 42 is inserted within a female spline contained in the threaded section 41. A threaded collar 39 is screwed to mate with the threads on the threaded member 41. An inside shoulder 45 on collar 39 shoulders against a projection 44 on member 40 and thereby locks the assembly as a splined and sealed unit. Torque is transmitted through the splines. 
     Referring now to FIG. 5, the wrenching device upper section 26 has the box section g securely attached to support members a. Die block c is attached to inner die carrier d. Blocks b and c are able to move inward or outward on guides h. Cylinder k when pressurized in chamber q moves block b into contact with tubular workpiece m. As block b engages workpiece m a reactionary force moves inner die carrier d in a direction away from workpiece m until die block c which is attached to die carrier d is forced to engage workpiece m. In operation, pressure in chamber q creates a gripping force which firmly engages serrated dies s against the workpiece m. In the reverse action, cylinder k is pressurized in chamber r causing die block b to move away from workpiece m. After partial travel, block b will contact stops e which will cause the body of cylinder k and the inner die carrier d to move inward toward the workpiece m. This action forces the die block c away from workpiece m. 
     Referring now to FIG. 7 which is a bottom view of the lower, rotatable section 31 of the wrenching device, the box section g is securely attached to circular guide plate f. Die block c is attached to inner die carrier d with pins p. Blocks b and c are able to move inwardly and outwardly, being aligned by guides h. Cylinder k when pressurized in chamber q moves block b to contact tubular workpiece m. As block b engages workpiece m, a reactionary force moves inner die carrier d in a direction away from the workpiece m until die block c engages workpiece m. In operation, pressure in chamber q creates a gripping force which firmly engages serrated dies s against workpiece m. 
     In the reverse action, the cylinder k is pressurized in chamber r causing die block b to move away from workpiece m. After partial travel, block b will contact stops e which causes the body of cylinder k to move toward the workpiece m. Since inner die carrier d is attached to cylinder k, die carrier d will move toward workpiece m and force block c away from the workpiece m, the force being transferred thru pins p which attach die block c to inner die carrier d. Torque arms t are securely attached to box section g. 
     Referring now to FIG. 8 which is a sectional view or the apparatus shown in FIG. 7, the circular guide plate f features a guide lip u which will be used in attaching the assembly of FIG. 7 to the upper section of the wrenching device shown in FIG. 5. 
     Referring now to FIG. 9, a typical section thru either the top wrenching section or the lower wrenching section is shown illustrating the method of attaching an inner die carrier d to a die block c using a pin p. 
     Referring now to FIG. 6, the cylinders v are affixed to the lower section z of the wrenching device through a clevis aa at the rod end. The barrel end is connected to the upper section BB through a hinged joint w and the reaction is restrained by the upper section BB. When the cylinders are energized, the lower section will rotate the centerline of the guided die blocks about axis y. The annular groove and tongue u and x align and secure the upper and lower halves together while allowing rotary motion. When the bolts B are removed the wrenching device is free to pivot in a horizontal plane about Point P as shown in FIG. 1. 
     With this invention, well drilling fluids enter the drill string through a conventional flexible hose connected to the swivel 11 shown in FIG. 1. The swivel has a hollow shaft through which fluids pass into the hollow shaft 30 of the top drive 10 and on through the hollow sections of the remaining subs or devices into the interior of the drill string. 
     The top drive apparatus according to the present invention compare very favorably with the prior art drive apparatuses. The following chart compares certain features (but not all) of a top drive according to the present invention to the top drive embodying features disclosed in U.S. Pat. No. 4,449,596 and to the Bowen ES-7 Electric Drilling Swivel: 
     
         ______________________________________               THE PRESENTPrior Art           INVENTION______________________________________Electrical power is conducted               Operated by hydraulic fluid.from the generating room to the               There is no danger ofunit through rubber covered               sparking. The hydraulicelectrical cables. Danger of               power unit is located in adamaging and sparking is ever               safe area.present. An accident at a timewhen well head gasses arepresent could be disasterous.Complete drilling system weighs               Complete system weighs 10approximately 20 tons.               tons or less.In the event of mechanical               Unit is designed to accom-failure requires complete &#34;rig               modate rapid replacement ofdown&#34;; the replacement of the               the hydraulic Top Drive.top drive assembly would be               Because of this featuremore complex.       several hours of down time               are saved.User confidence in the reliability               Reliability of this systemof this unit is not high.               would allow users to elimin-Consequently, all installations               ate the rotary tableare equipped with a conventional               drive systems; spare(rotary table) drive system on               hydraulic motors and com-&#34;standby&#34;.          ponents are the only               &#34;back-up&#34; equipment.               This saves hundreds               of thousand dollars rig cost.Hazardous area certificates are               Electrical devices are locatedrequired for the numerous               below the drill floor in asafety devices used to monitor               pressured safe room whichsystems designed to render this               already exists. The multitudeunit safe for use in a hazardous               of monitoring devices usedlocation. This is time con-               on the electric drivesuming and expensive.               are not required.During drilling, excessive bit               Fluid power because of itsweight or hole friction stalls               inherent nature is muchout the electric motor and               smoother. The mechanics ofstops the drill bit. Common               the moving fluid are suchpractice is to reduce bit               that acceleration afterweight. Since full electrical               stall will be smoother andpotential remains applied, the               uniform. Less damage todrill suddenly accelerates from               drill hole and equipmentzero to up to 250 R.P.M. in a               are realized.matter of seconds. This causesover-tightening of tool jointthreads and ruins the drillpipe. Also the drill stringmay whip and damage the wall ofthe hole. Mechanical reactionis transmitted to the derrickthrough the support mechanismsand this vibration damages thestructure and is very noisy.Air purging the inside of the               No purging is requiredelectric drilling motor is               because there is no airrequired at initial start-up               cooling system.and at every time a safetydevice actuates. This mayrequire 10 to 30 minutes.On units so equipped there is a               No such system is required.danger of water leaking intothe electric motor followingany damage or corrosive failureof the water to air heat exchangerused to cool the motor air.These systems are requiredwherever you find stringentsafety measures such as NorthSea Platforms. This can causethe motor to fail.Making drill pipe connection:               The pipe handling device onThe drill pipe is picked up by               this unit has a hydraulic liftthe elevator bowl and the lower               to engage the thread. Properend stabbed in the previous               adjustment will ensurepipe. Human skill is then               minimal pressure on therequired to ease the drive               threads. This is much quickershaft down into the thread to               than when the driller hasscrew it up. Thread damage can               to execute skill and judg-occur.              ment making up each               joint of pipe.When picking up a length of               Perfect alignment anddrill pipe whose end is pro-               orientation of the pipetruding about 3 ft. above the               handling mechanism isdrill floor, the pipe handler               achieved via mechanicalmust be tilted outward. Since               stops and cylinders to createthe bowl of the pickup tool is               the necessary movement.swiveled, the angle is incorrect               The latch is spring loadedfor the pipe. Also the latches               to automatically lock whenon the pickup tool must be               the pipe is loaded. A cylindermanually closed which takes               will actuate the latch to thetime.               open position. This is by               remote control which is               much safer. This system is               also much faster than the               manual method.Cost much more.     This system costs much less.               This does not take into ac-               count the equipment which               an operator does not have               to buy, such as extra swivel               and/or rotary table drive               which would make the               savings several hundred               thousand dollars.Installing this unit on land               Retrofit to any existingrigs or retrofitting to off-               drilling rig can be accom-shore rigs is very complicated               plished much easier becausebecause of size and different               of size and weight as wellsystem.             as simplicity of design.The closed circuit air cooling               No brushes are used.system collects carbon dustwhich erodes from the bushes.This can lead to internalshorting.Repeated stalling of the main               No such stalling problem.electric motor especially formore than a few moments, underhigh current will damage thearmature and subsequent rota-tion will lead to failure.______________________________________ 
    
     Also, the top drive apparatus of the present invention compares favorably to a top drive embodying certain features of the device disclosed in the prior art U.S. Pat. No. 4,449,596 in the following respects: 
     
         ______________________________________Prior Art          The Present Invention______________________________________Requires two circulating              Only one swivel is required.swivels because one is in-              Current list price for a 500tegral with power sub and one              ton swivel (Continentalmust be used when unit is              Emsco): $43,290.00rigged down.Requires explosion proof              Hydraulic oil is cooled bycooling air system. Present              rig supplied water beingdesign uses blower mounted on              circulated through an oilsupport dolly or drill floor              cooler. This equipment isand air is conducted through              located in an existing safe8&#34; flexible rubber duct.              location.This lightweight duct isoften windblown and damagedfrom hanging on the rigstructure. Hot air is ex-hausted to atmosphere creatinga hazardous condition.Documentation for the alternatingcurrent fan motor and approvalfor the D.C. drive motor istime consuming and expensive.The overall height, width and              This unit requires less thandepth is much greater; requires              36 ft.approximately 46 ft. ofvertical derrick height.The unit does not have a              Counterbalance mechanism&#34;rise and fall&#34; mechanism to              is provided.minimize load on drill stemthreads when unscrewing.Unit must swung back in              All normal drilling andorder to install well casing.              casing installation is done              with standard unit.______________________________________ 
    
     While certain specific embodiments of the present invention have been disclosed, the invention is not limited to these particular forms, but is applicable to all variations which fall within the scope of the following claims