ADJUSTABLE BREAKOUT WRENCH WITH MESHING JAWS FOR USE IN A DRILLING RIG

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the filing benefit of U.S. Provisional Application Ser. No. 63/627,379, filed Jan. 31, 2024, the disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This application relates generally to drilling systems and methods, and more particularly to the jaws of a breakout wrench in a drilling rig and methods of using same.

BACKGROUND

Drilling technologies and systems play a pivotal role across diverse industries, including the extraction of natural resources, subsurface exploration, and geothermal construction, for example. Sonic drilling is a notable technology in this realm, where a drill pipe or drill string is advanced into the ground by a drilling rig equipped with a sonic drill head. The sonic drill head subjects the drill string to acoustic vibrations that aid in fluidizing the ground beneath the drill string, facilitating easier penetration of the drill string to greater depths. Fluid circulation is often employed in sonic drilling processes, particularly when obtaining and analyzing core samples.

Drilling rigs in general, and particularly sonic drilling rigs, are complex pieces of machinery that require precision, reliability in their components, and ease of operability. Among these crucial components is the breakout wrench, which is essential for the efficient assembly and disassembly of drill string components. In particular, a breakout wrench enables the seamless connection and disconnection of drill pipe in a drill string during drilling operations. To that end, breakout wrenches are designed to manage the torque-intensive process of connecting and disconnecting drill pipes without causing damage to the pipes during the process.

However, conventional breakout wrenches encounter limitations in their design, specifically in the functionality of the jaws that engage and grip the drill pipe. In particular, existing breakout wrenches often necessitate the manual swapping of jaws to accommodate the range of pipe diameters required for drilling. For instance, a breakout wrench with a large fixed jaw size suitable for a 10-inch diameter drill pipe may not be compatible with a 4-inch diameter drill pipe, as the large sized jaws would bottom out before sufficiently closing to grasp the 4-inch drill pipe. The large sized jaws suitable for the 10-inch diameter pipe would need to be manually replaced with smaller sized jaws suitable for the 4-inch diameter pipe. The need to manually replace jaws introduces inefficiencies, delays, and heightened complexity to the overall pipe connection and disconnection process in drilling operations.

To avoid the inconvenience of manually changing jaws during operations, a common practice involves using a single size of pipe jaw to accommodate a range of drill pipe sizes. However, due to the substantial clamping forces exerted by breakout wrenches, this work around with a universal jaw approach can lead to deformations or elongation (“egging”) of the drill pipe. This is especially apparent when the clamping force is unevenly distributed around the drill pipe, such as when a smaller-sized jaw is utilized with a large-diameter drill pipe.

To meet the demands of modern drilling practices, there is a need for a breakout wrench equipped with jaws that provide adaptability to various pipe diameters, eliminating the requirement to manually swap out pipe jaws. Additionally, there is a need for jaws capable of clamping a broader range of drill pipe while maintaining an wide clamping angle to ensure a more evenly distributed clamping force around the drill pipe, thereby minimizing the likelihood of deformation or “egging.”

SUMMARY

To achieve these and other technical objectives, a breakout wrench for a drilling rig is disclosed. According to one embodiment, the breakout wrench includes a wrench body, a first jaw and a second jaw. The first jaw is operatively supported by the wrench body and movable relative to the wrench body by a first actuator. The first jaw includes a male jaw block with a grip surface and a female jaw block with a grip surface, The second jaw of the breakout wrench is operatively supported by the wrench body and movable relative to the wrench body by a second actuator. The second jaw includes a male jaw block with a grip surface and a female jaw block with a grip surface. A jaw opening is defined between the first jaw and the second jaw, and the first jaw and the second jaw are configured to mesh together to vary a size of the jaw opening. To this end, a drilling rig may include the breakout wrench.

According to one aspect, the first jaw and the second jaw may be arranged on the wrench body so as to be mirrored opposites. The first jaw and the second jaw may also be arranged so as to be diametrically opposed about the wrench body. Additionally, a longitudinal axis of the first jaw may be generally parallel to a longitudinal axis of the second jaw.

According to another aspect, the first jaw and the second jaw may mesh together at two separate locations spaced apart along a length of the first jaw and the second jaw. In that regard, the female jaw block of the first jaw may be configured to receive the male jaw block of the second jaw and the female jaw block of the second jaw may be configured to receive the male jaw block of the first jaw to mesh the first jaw and the second jaw together.

According to yet another aspect, the grip surface of the male jaw block of the first jaw may be angled relative to the grip surface of the female jaw block to define a first jaw block angle. The male jaw block of the second jaw may be angled relative to the grip surface of the female jaw block to define a second jaw block angle. For example, the first jaw block angle and the second jaw block angle may be within a range of between about 100° to about 120°, and the first jaw block angle and the second jaw block angle may be about 110°.

According to another embodiment, a method of operating a breakout wrench for a drilling rig is disclosed. The breakout wrench includes a wrench body, a first jaw operatively supported by the wrench body and movable relative to the wrench body by a first actuator, and a second jaw operatively supported by the wrench body and movable relative to the wrench body by a second actuator. To that end, a jaw opening is defined between the first jaw and the second jaw. The method includes operating the breakout wrench to close the first jaw and the second jaw to define a first jaw opening configured to receive drill pipe having a first diameter. The method further includes operating the breakout wrench to further close the first jaw and the second jaw to define a second jaw opening configured to receive drill pipe having a second diameter. The first jaw and the second jaw mesh together to define the second jaw opening.

According to one aspect, the first diameter of drill pipe is larger compared to the second diameter of drill pipe. In another aspect, the method includes operating the breakout wrench to break or establish a connection between drill pipe having the first diameter. The method may also include operating the breakout wrench to break or establish a connection between drill pipe having the second diameter. According to another aspect, the first jaw and the second jaw may move in parallel during operation of the breakout wrench.

In one aspect, the first jaw may include a male jaw block with a grip surface and a female jaw block with a grip surface. The second jaw may include a male jaw block with a grip surface and a female jaw block with a grip surface. The method may further include operating the breakout wrench to fit the first jaw and the second jaw together such that the female jaw block of the first jaw receives the male jaw block of the second jaw and the female jaw block of the second jaw receives the male jaw block of the first jaw. In another aspect, the method may further include engaging the drill pipe with the first jaw and second jaw at four separate contact locations about the drill pipe. For example, the first jaw may define two contact locations about the drill pipe and the second jaw may define two contact locations about the drill pipe.

According to another embodiment, a jaw for a breakout wrench is disclosed. The jaw includes a mounting block that extends from a first end to a second end to define a longitudinal axis of the jaw, a male jaw block attached to the mounting block and including a grip surface and a finger that projects from the male jaw block toward the first end of the mounting block, and a female jaw block attached to the mounting block and including a grip surface and a slot. The slot is sized to receive the finger of another male jaw block. The slot may define a pair of arms that project from the female jaw block toward the second end of the mounting block. A breakout wrench and/or a drilling rig may include the jaw.

In one aspect, the grip surface of the male jaw block may be angled within a range of between about 30° to about 40° relative to the longitudinal axis of the mounting block. The grip surface of the female jaw block may also be angled within a range of between about 30° to about 40° relative to the longitudinal axis of the mounting block. In another aspect, the male jaw block may include a male grip insert removably attached to the male jaw block. The male grip insert defines the grip surface of the male jaw block. Additionally, the female jaw block may include a female grip insert removably attached to the female jaw block. The female grip insert defines the grip surface of the female jaw block. For example, the male grip insert may define part of the finger and the female grip insert may define part of the slot. Further, the grip surface of the male jaw block and the female jaw block may include a plurality of splines.

In yet another aspect, the jaw may include a locking block attached to mounting block between the between the male jaw block and the female jaw block. The locking block is used to secure the male grip insert to the male jaw block and the female grip insert to the female jaw block.

The various embodiments and elements described above can be combined in any manner consistent with the scope of this invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Various additional features and advantages of the invention will become more apparent to those of ordinary skill in the art upon review of the following detailed description of one or more illustrative embodiments taken in conjunction with the accompanying drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the invention and, together with the general description given above and the detailed description given below, serve to explain the one or more embodiments of the invention.

FIG. 1 is a perspective view of a drilling rig used for sonic drilling, which includes an exemplary breakout wrench assembly.

FIG. 2 is a perspective view of a jaw block for use with a breakout wrench of the drilling rig of FIG. 1, in accordance with an embodiment of the invention.

FIG. 3 is a disassembled perspective view of the jaw block of FIG. 2.

FIG. 4 is a cross-sectional view of the jaw block, taken along line 4-4 of FIG. 2.

FIG. 5A is a diagrammatic top view of a breakout wrench equipped with a pair of jaw blocks, illustrating movement of the jaw blocks to grasp a large-diameter drill pipe.

FIG. 5B is a diagrammatic top view of the breakout wrench of FIG. 5A, illustrating the large-diameter drill pipe grasped between the pair of jaw blocks.

FIG. 5C is a perspective view of the pair of jaw blocks of FIG. 5A, with the diagrammatic detail of the breakout wrench removed for clarity.

FIG. 5D is a perspective view of the pair of jaw blocks of FIG. 5B, with the diagrammatic detail of the breakout wrench removed for clarity.

FIG. 6A is a diagrammatic top view of a breakout wrench equipped with a pair of jaw blocks, illustrating movement of the jaw blocks to grasp a small-diameter drill pipe.

FIG. 6B is a diagrammatic top view of the breakout wrench of FIG. 6A, illustrating the small-diameter drill pipe grasped between the jaw blocks.

FIG. 6C is a perspective view of the pair of jaw blocks of FIG. 6B, with the diagrammatic detail of the breakout wrench removed for clarity.

DETAILED DESCRIPTION

With reference to the Figures, and in particular FIG. 1, an exemplary drilling rig 10 is shown with which embodiments of the present invention may be used. The exemplary drilling rig 10 shown in this example includes equipment capable of sonic drilling (including but not limited to sonic percussive drilling) and/or non-sonic drilling (e.g., air hammer drilling, water hammer drilling, rotational bit drilling, and the like) to produce a hole in the ground. Further, drilling rig 10 must accommodate a wide range of drill pipe diameters to suit these various drilling applications. As used herein, the term “drill pipe” encompasses any component capable of constituting part of a drill string. This includes, for example, casing, drill rods, drill bits, core barrels, subs (subassemblies), collars, stabilizers, or any other types of drill steel as comprehended by individuals skilled in the art. While aspects of the present invention are shown and described for use with one exemplary sonic drilling rig 10, it will be understood that the same inventive concepts related to aspects of the present invention may be implemented with different drilling systems and methods without departing from the scope of the invention. To this end, one advantage of the present invention is tailoring the clamping jaws of a breakout wrench to not require changing over an entire range of typical pipe diameters used with sonic drills, so as to remove this added step in the operational process between or during drill projects.

With continued reference to FIG. 1, the drilling rig 10 may be track-mounted and generally small in footprint, similar to the TSi 150CC Sonic Drill Rig (also entitled the “Compact Crawler”), commercially available from Terra Sonic International, of Marietta, Ohio. To this end, the drilling rig 10 includes a support framework 12 mounted atop the track rollers 14, with a sonic drill head 16 supported on a pivotable drill boom 18 that is also mounted on the framework 12. The drill boom 18 is movable between a stowed position in which the boom 18 extends generally horizontally and a drilling position in which the drill boom 18 extends generally vertically at a front end of the drilling rig 10, as shown in FIG. 1. During operation of the drilling rig 10, the drill boom 18 defines a drill axis A1 along which a drill string is advanced via the sonic drill head 16 into a borehole in the ground. As shown in FIG. 1, the drill axis A1 is generally vertical (i.e., 90° relative to a ground surface), however, the drill axis A1 may be angled relative to the ground surface. One of the types of drilling enabled by the drilling rig 10 is sonic drilling, in which generation of sound waves is conducted to help a casing, for example, successfully penetrate through the rock or soil foundation underneath the drilling rig 10. To this end, the sonic drill head 16 is configured to produce vibrations with frequencies such as in the 50 Hz to 150 Hz range, and the specific frequency chosen during operation is generally coincident with a resonant frequency of the casing string being inserted into the earth. By applying such resonant frequencies, which are in the sonic range, the vibrations are transmitted effectively to the drill bit or casing end, even when more weight and length are added as the casing string extends significant distances into the ground.

With continued reference to FIG. 1, the drilling rig 10 also includes a breakout wrench assembly 20 for applying torque to the drill string in order to couple and uncouple components of the drill string, referred to herein as drill pipe. Specifically, the breakout wrench assembly 20 is operatively supported by the drill boom 18 and includes a pair of breakout wrenches 22, such as an upper breakout wrench 22 and a lower breakout wrench 22. One or both breakout wrenches 22 may be rotatable in a direction about the drill axis A1 to either break or establish a connection between drill pipe in the drill string. In this context, the drill string is positioned through the pair of breakout wrenches 22 during operation of the drilling rig 10. As the drill string is advanced or removed from the borehole by the drill head 16, joints between drill pipes—that collectively form the drill string—pass through the pair of breakout wrenches 22. To disconnect a joint between two drill pipes of the drill string, the joint is positioned between the upper and lower breakout wrenches 22, which are then operated to individually grasp and secure each drill pipe. The upper breakout wrench 22 may then be rotated relative to the lower breakout wrench 22 to break the connection between the two grasped drill pipes.

Each breakout wrench 22 includes a horseshoe-shaped wrench body 24 that is operatively supported by the drill boom 18. Each wrench body 24 includes a pair of jaws 26 each being operatively supported by the wrench body 24 and movable relative to the wrench body 24 by a respective actuator 28. The actuators 28 may be linear actuators, such as a hydraulic cylinder or pneumatic actuator, for example. In that regard, movement of the jaws 26 of each breakout wrench 22 is generally in a direction perpendicular to the drill string and the drill axis A1. To that end, during operation of the breakout wrench assembly 20, drill pipe is configured to be grasped or clamped between the pair of jaws 26 of each breakout wrench 22, as will be described in further detail below. The drilling rig 10 further includes a control station 30 for monitoring the operational parameters of the drilling rig 10 and for controlling the drilling rig 10 and its components, such as the breakout wrench assembly 20. The control station 30 is provided at the end of the drilling rig 10 proximate the drill boom 18.

The jaws 26 of each breakout wrench 22 described above may be replaced with jaws 32 in accordance with embodiments of the present invention. As briefly described above, various drill pipe diameters may be utilized within a drill string, determined by factors such as geological conditions, drilling rig 10 capacity, torque and rotation requirements, fluid circulation efficiency, and drilling depth, for example. In the context of sonic drilling, drill pipe diameters typically range from 1 inch to 12 inches. Turning now to FIGS. 2-5, a jaw block (referred hereafter as a “jaw”) 32 for a breakout wrench 22 is shown in accordance with embodiments of the present invention. The jaw 32 addresses the need to accommodate a wide range of drill pipe diameters without requiring the manual change-out of jaws. In that regard, a breakout wrench 22 may be equipped with a pair of jaws 32 that enable the breakout wrench 22 to receive and securely grip a range of drill pipe diameters. As the jaws 32 close around the drill pipe, especially drill pipe at the lower (i.e., smaller) end of the range of drill pipe diameters, the jaws 32 are configured to “mesh” or fit together in an overlapping or interlocking engagement about the drill pipe, a process also referred to as “scissoring.” Simultaneously, the jaws 32 maintain a broad clamping angle that prevents damage to the drill pipe, such as “egging,” across the desired range of graspable drill pipe diameters. In the embodiment shown, the jaws 32 provide the breakout wrench 22 with the capability to grip a wide range of drill pipes, ranging from 1 inch to 12 inches in diameter. In one embodiment, the jaws 32 may be configured to accommodate drill pipes ranging in diameter from about 1.75 inches to about 10.5 inches. In another embodiment, the jaws 32 may be configured to accommodate drill pipes ranging in diameter from about 3.5 inches to about 12 inches. To this end, it is recognized that adjusting the jaw size to accommodate various other diameters of drill pipe is feasible and falls within the scope of the present invention.

Referring now to FIGS. 2-4, the jaw 32 includes a mounting block 34 to which a male jaw block 36 and a female jaw block 38 are removably attached. The male and female jaw blocks 36, 38 each include a grip surface 40, 42, respectively, that is configured to engage drill pipe during use. In that regard, the male and female jaw blocks 36, 38 are configured such that the grip surfaces 40, 42 are angled to form a generally V-shaped pocket 44 between the male and female jaw blocks 36, 38 that is configured to receive a portion of the drill pipe therein. As will be described in further detail below, the pockets 44 of a pair of jaws 32 in the breakout wrench 22 collectively form a jaw opening 46 (e.g., FIG. 5A) through which drill pipe of the drill string is configured to be received. The breakout wrench 22 is operated to close the jaws 32 about drill pipe positioned in the jaw opening 46, with the jaws 32 being configured to mesh together or interlock about the drill pipe, particularly when grasping a small diameter of drill pipe.

With continued reference to FIGS. 2-4, the mounting block 34 is elongated and extends from a first end 48 to an opposite second end 50, defining a longitudinal axis A2 of the jaw 32. In the embodiment shown, the mounting block 34 includes a pair of sidewalls 52, a pair of end walls 54, a base 56, and a top 58 to define a generally rectangular prism shape of the mounting block 34. However, other polygonal configurations of the mounting block 34 are possible, and the drawings are not intended to be limiting in that regard. The mounting block 34 is configured to both support components of the jaw 32 and secure the jaw 32 to the breakout wrench 22. With regard to the latter, the mounting block 34 includes a socket 60 formed in its base 56 (e.g., FIG. 4) that is configured to accommodate a piston arm 62 of an actuator 28 (e.g., FIG. 6A). Additionally, the mounting block 34 includes a pair of aligned bores 64, each extending through a corresponding sidewall 52 of the mounting block 34 to the socket 60. As shown in FIGS. 6A and 6B, the piston arm 62 fits into the socket 60, allowing the insertion of a bolt or pin through the bores 64 to removably attach the jaw 32 to the actuator 28 of the breakout wrench 22. As shown in FIG. 4, the base 56 of the mounting block 34 may include a number of counterbores 66. The counterbores 66 may also be used for attachment of the jaw 32 to the breakout wrench 22. Additionally or alternatively, the counterbores 66 may serve as a weight reducing means to reduce the overall weight of the jaw 32.

With continued reference to FIGS. 2-4, the top 58 of the mounting block 34 is configured to receive the male jaw block 36 and the female jaw block 38. As shown in FIG. 3, the top 58 is divided into two pads 68 by a central keyway 70 that extends perpendicular to the longitudinal axis A2 of the jaw 32 and between sidewalls 52 of the mounting block 34. The keyway 70 is configured to receive a locking block 72 used to secure parts of the male and female jaw blocks 36, 38, as will be described in further detail below. Each pad 68 is configured to receive a respective male jaw block 36 or female jaw block 38, as shown. To facilitate the attachment of male and female jaw blocks 36, 38 to the pads 68, each pad 68 includes an alignment pin 74 and a threaded bore 76. The alignment pin 74 is used to align the respective male or female jaw block 36, 38 on each pad 68 and the threaded bore 76 is configured to receive a threaded fastener 78 to secure the male or female jaw block 36, 38 to each respective pad 68. In the embodiment shown, the alignment pin 74 and threaded bore 76 are located proximate the keyway 70. However, the alignment pin 74 and threaded bore 76 may be located elsewhere on each pad 68, such as centered on the pad 68 between the keyway 70 and an end 48, 50 of the mounting block 34, for example.

Details of the male jaw block 36 and the female jaw block 38 will now be described with continued reference to FIGS. 2-4. In that regard, the male jaw block 36 is generally triangular in shape and includes a male grip insert 80 that defines the grip surface 40 of the male jaw block 36. As shown, the male jaw block 36 includes a base wall 82, a back wall 84, and an angled front 86 that extends between the back wall 84 and the base wall 82 to define the generally triangular shape of the male jaw block 36. In particular, the male jaw block 36 generally defines a right triangle, with the angled front 86 and the back wall 84 intersecting at its apex. The male jaw block 36 includes a finger 88 that projects from a body 90 of the male jaw block 36, with the back wall 84 defining a height of the finger 88. In that regard, the finger 88 forms the apex of the male jaw block 36. As shown, the finger 88 projects from the body 90 of the male jaw block 36 to define a pair of shoulders 92, with one shoulder 92 being located on either side of the finger 88 and each shoulder 92 extending a length from the angled front 86 of the male jaw block 36 to the base wall 82. The shoulders 92 are located generally at a midpoint along the angled front 86, as shown. The finger 88 has a width, as measured between sidewalls 94, that is less than a width of the body 90 of the male jaw block 36, as measured between sidewalls 96. The finger 88 has a length measured between the shoulders 92 and the back wall 84 of the male jaw block 36.

As best shown in FIG. 3, the male jaw block 36 includes a recess 98 formed in the angled front 86, spanning part of the finger 88 and the body 90 of the male jaw block 36, that is configured to receive the male grip insert 80. With respect to the body 90 of the male jaw block 36, the recess 98 defines a pair of edge walls 100 that each extend along the angled front 86 from the base wall 82 to a respective shoulder 92. With respect to the finger 88 of the male jaw block 36, the recess 98 terminates short of the apex at an undercut 102. The undercut 102 and the edge walls 100 are configured to retain the male grip insert 80 within the recess 98. As shown, a majority of the finger 88 includes the recess 98, and the recess 98 extends from the undercut 102 to an opening to the recess 98 at the base wall 82 of the male jaw block 36.

With reference to FIGS. 3 and 4, the body 90 of the male jaw block 36 includes an alignment bore 104 and a mounting bore 106, each extending in a direction from the angled front 86 to the base wall 82. The alignment bore 104 is configured to receive the alignment pin 74 of the mounting block 34 for aligning the male jaw block 36 on the pad 68, and the mounting bore 106 is configured to receive the fastener 78 therethrough for securing the male jaw block 36 to the pad 68 of the mounting block 34, as described above. To that end, the mounting bore 106 includes a counterbore, allowing the fastener 78 to be fully recessed into the mounting bore 106 to secure the male jaw block 36 to the mounting block 34. As shown in FIG. 4, this ensures that the male grip insert 80 may be received into the recess 98 unobstructed by the fastener 78.

The male grip insert 80 is sized to be received within the recess 98 in the male jaw block 36, as shown in, e.g., FIG. 2. In that regard, the male grip insert 80 includes a body portion 108, a finger portion 110, and a length between a first end 112, defined by the finger portion 110, and an opposite second end 114, defined by the body portion 108. The finger portion 110 corresponds with the profile of the recess 98 formed in the finger 88 of the male jaw block 36. Consequently, when placed within the recess 98, the finger portion 110 of the male grip insert 80 integrates seamlessly with the finger 88 of the male jaw block 36. The body portion 108 of the male grip insert 80 generally corresponds to the profile of the recess 98 formed in the body 90 of the male jaw block 36. As best shown in FIG. 4, the first end 112 of the male grip insert 80 is configured to be received within the undercut 102 in the finger 88 of the male jaw block 36. The second end 114 of the male grip insert 80 is configured to be engaged by the locking block 72 to secure the male grip insert 80 within the recess 98, as will be described in further detail below.

The male grip insert 80 includes a plurality of elongated teeth or splines 116 that extend between sides of the male grip insert 80. The teeth 116 extend generally parallel to one another and are spaced evenly apart along the length of the male grip insert 80. As briefly described above, the male grip insert 80 defines the grip surface 40 of the male jaw block 36 that is configured to engage the drill pipe during use. Specifically, the teeth 116 are configured to engage and grip the drill pipe during use. To that end, the teeth 116 may wear out from normal use, necessitating the replacement of the male grip insert 80. Thus, the male grip insert 80 may be considered a wear part.

Referring again to FIGS. 2-4, and similar to the male jaw block 36, the female jaw block 38 is generally triangular in cross-sectional shape and includes a female grip insert 118 that defines the grip surface 42 of the female jaw block 38. As shown, the female jaw block 38 includes a base wall 120, a back wall 122, and an angled front 124 that extends between the back wall 122 and the base wall 120 to define the generally triangular shape of the female jaw block 38. In particular, the female jaw block 38 generally defines a right triangle, with the angled front 124 and the back wall 122 intersecting at its apex. The female jaw block 38 includes a slot 126 formed in the back wall 122 that is sized to receive the finger 88 of another jaw 32, as will be described in further detail below. The slot 126 extends from an opening 128 in the back wall 122 to a base 130, forming a pair of arms 132 that project from a body 134 of the female jaw block 38. In particular, each arm 132 extends from the body 134 to the back wall 122, with a height peaking at the apex of the female jaw block 38. As shown, the opening 128 to the slot 126 extends for the entire height of the back wall 122, from the base wall 120 to the angled front 124. The base 130 of the slot 126, located generally at a midpoint along the angled front 124 between the base wall 120 and the back wall 122, extends from the angled front 124 to the base wall 120.

As best shown in FIGS. 3 and 4, the female jaw block 38 includes a recess 136 formed in the angled front 124 of the female jaw block 38, spanning part of the arms 132 and the body 134, that is configured to receive the female grip insert 118. With respect to the body 134 of the female jaw block 38, the recess 136 defines a pair of edge walls 138, each extending along the angled front 124 and along a respective arm 132. The recess 136 is also formed in a portion of the arms 132 of the female jaw block 38. However, the recess 136 terminates short of the apex of the female jaw block 38 to form an undercut 140 in each arm 132 that is configured to retain the female grip insert 118 within the recess 136. As shown, a majority of each arm 132 includes the recess 136, and the recess 136 extends from the undercut 140 in each arm 132 to an opening to the recess 136 at the base wall 120 of the female jaw block 38.

With continued reference to FIGS. 3 and 4, the body 134 of the female jaw block 38 includes an alignment bore 142 and a mounting bore 144, each extending in a direction from the angled front 124 to the base wall 120. The alignment bore 142 is configured to receive the alignment pin 74 of the mounting block 34 for aligning the female jaw block 38 on the pad 68 of the mounting block 34, and the mounting bore 144 is configured to receive the fastener 78 therethrough for securing the female jaw block 38 to the mounting block 34, as described above. To that end, the mounting bore 144 includes a counterbore, allowing the fastener 78 to be fully recessed into the mounting bore 144 to secure the female jaw block 38 to the mounting block 34. As shown in FIG. 4, this ensures that the female grip insert 118 may be received into the recess 136 unobstructed by the fastener 78.

The female grip insert 118 is sized to be received within the recess 136 of the female jaw block 38, as shown in FIG. 2, for example. In that regard, the female grip insert 118 includes a body portion 146, a pair of arm portions 148, and a length measured between a first end 150, defined by the arm portions 148, and an opposite second end 152, defined by the body portion 146. The arm portions 148 correspond to the profile of the recess 136 formed in each respective arm 132 of the female jaw block 38 and the body portion 146 generally corresponds to the profile of the recess 136 formed in the body 134 of the female jaw block 38. In that regard, the female grip insert 118 defines part of the slot 126 formed in the female jaw block 38. As best shown in FIG. 4, each arm portion 148 of the female grip insert 118 is configured to be received within a respective undercut 140 in an arm 132 of the female jaw block 38. The second end 152 of the female grip insert 118 is configured to be engaged by the locking block 72 to secure the female grip insert 118 within the recess 136, as will be described in further detail below.

Like the male grip insert 80, the female grip insert 118 also includes a plurality of elongated teeth or splines 154 that extend between sides of the female grip insert 118. The teeth 154 extend generally parallel to one another and are spaced evenly apart along the length of the female grip insert 118. As briefly described above, the female grip insert 118 defines the grip surface 42 of the female jaw block 38 that is configured to engage the drill pipe during use. Specifically, the teeth 154 are configured to engage and grip the drill pipe during use. For the same reasons set forth above, the female grip insert 118 may also be considered a wear part.

Once the male and female jaw blocks 36, 38 have been attached to the mounting block 34 and the male and female grip inserts 80, 118 positioned in each recess 98, 136, respectively, the locking block 72 may be attached to the mounting block 34. The locking block 72 secures the male grip insert 80 within the recess 98 in the male jaw block 36 and the female grip insert 118 within the recess 136 in the female jaw block 38. As shown in FIGS. 2-4, the locking block 72 is generally trapezoidal in shape, with a pair of angled sidewalls 156 that extend along a length of the locking block 72. A bore 158 extends through the locking block 72, from top to bottom, to accommodate a fastener 160 used for securing the locking block 72 to the mounting block 34. The bore 158 may include a counterbore, allowing the fastener 160 to be fully recessed into the bore 158 to secure the locking block 72 to the mounting block 34.

The locking block 72 is configured to slide lengthwise into the keyway 70 formed in the mounting block 34. In this context, the keyway 70 includes a pair of edges 162 that engage the angled sidewalls 156 of the locking block 72, effectively retaining the locking block 72 within the keyway 70. When positioned within the keyway 70 (e.g., FIGS. 2 and 4), each angled sidewall 156 of the locking block 72 engages a respective second end 114, 152 of either the male or female grip insert 80, 118. This engagement securely holds the male and female grip inserts 80, 118 in place within their respective recesses 98, 136. To attach the locking block 72 to the mounting block 34, the fastener 160 is inserted through the bore 158 in the locking block 72 and threaded into a threaded bore 164 in the keyway 70.

As briefly described above, the male jaw block 36 and the female jaw block 38 form a generally V-shaped pocket 44 to receive a portion of drill pipe therein. As best shown in FIG. 4, the male jaw block 36 is attached to the mounting block 34 with the back wall 84 arranged proximate the first end 48 of the mounting block 34, with the finger 88 extending toward the first end 48. As a result, the angled front 86 of the male jaw block 36, and in particular the male grip insert 80, is angled downwardly from a high point at the first end 48 of the mounting block 34 to a low point adjacent the keyway 70. Similarly, the female jaw block 38 is attached to the mounting block 34 with the back wall 122 arranged proximate the second end 50 of the mounting block 34, with the arms 132 extending toward the second end 50. As a result, the angled front 124 of the female jaw block 38, and in particular the female grip insert 118, is angled or downwardly from a high point at the second end 50 of the mounting block 34 to a low point adjacent the keyway 70. Thus, the base of the V-shaped pocket 44 is located at the keyway 70 and generally positioned at the center of the mounting block 34 between the first and second ends 48, 50.

With continued reference to FIG. 4, the grip surface 40 of the male jaw block 36, as defined by the male grip insert 80, is angled relative to the longitudinal axis A2 of the mounting block 34 to define a male jaw block angle θ₁. The male jaw block angle θ₁ may be within a range of between about 20° to about 50°, and more particularly between about 30° to about 40°, and preferably about 35°. Similarly, the grip surface 42 of the female jaw block 38, as defined by the female grip insert 118, is angled relative to the longitudinal axis A2 of the mounting block 34 to define a female jaw block angle θ₂. The female jaw block angle 62 may be within a range of between about 20° to about 50°, and more particularly between about 30° to about 40°, and preferably about 35°. Described another way, the grip surface 40 of the male jaw block 36 is angled relative to the grip surface 42 of the female jaw block 38 to define a jaw block angle θ₃. The jaw block angle 63 may be within a range of between about 80° to about 140°, and more particularly between about 100° to about 120°, and preferably about 110°.

Having now described certain details of the jaw 32, operation of a breakout wrench 22 equipped with a pair of jaws 32 to grasp drill pipe of varying diameters will now be described with respect to FIGS. 5A-6C. In particular, FIGS. 5A-5D illustrate a large diameter drill pipe 166, such as a 12 inch casing, being grasped between the pair of jaws 32a, 32b. FIGS. 6A-6C illustrate a small diameter drill pipe 168, such as a 3.5 inch drill rod, being grasped between the pair of jaws 32a, 32b. In FIGS. 5A-6C, the addition of a suffix (i.e., “a”, “b”, etc.) is used to identify duplicate parts, such as a first jaw 32a and a second jaw 32b of the breakout wrench 22.

Referring now to FIGS. 5A and 5B, a schematic representation of one of the upper or lower breakout wrenches 22 of the drilling rig 10 is shown, equipped with a pair of jaws 32a, 32b. The wrench body 24, being generally shaped like a horseshoe, includes a first arm 170 and a second arm 172 that define an opening 174 for accepting drill pipe of the drill string so that the drill pipe may be arranged between the pair of jaws 32a, 32b. In that regard, the wrench body 24 includes the first jaw 32a operatively coupled to the actuator 28 on the first arm 170 of the wrench body 24 and the second jaw 32b operatively coupled to the actuator 28 on the second arm 172 of the wrench body 24. When so arranged, the longitudinal axis A2 of the first jaw 32a is generally parallel to the longitudinal axis A2 of the second jaw 32b. Stated another way, the first jaw 32a and the second jaw 32b are supported by the wrench body 24 so as to be diametrically opposed. Further, the first jaw 32a and the second jaw 32b are arranged on the wrench body 24 so as to be mirrored opposites. That is, the first jaw 32a is arranged such that the male jaw block 36 is closest a terminal end 176 of the first arm 170 of the wrench body 24. The orientation of the second jaw 32b is 180 degrees opposite to that of the first jaw 32a, with the female jaw block 38 of the second jaw 32b being arranged closest a terminal end 178 of the second arm 172 of the wrench body 24. This mirrored opposite arrangement of the jaws 32a, 32b permits meshing or interlocking of the jaws 32a, 32b about certain diameter of drill pipe, as will be described in further detail below.

With reference to FIG. 5A, the drill pipe 166 is located between the first arm 170 and the second arm 172 of the breakout wrench 22, generally coaxial with the drill axis A1, such that the pair of jaws 32a, 32b are diametrically opposed about the circumference of the drill pipe 166. Specifically, the drill pipe 166 is located within the jaw opening 46 between the pair of jaws 32a, 32b. FIG. 5A shows the jaws 32a, 32b in an open position to define a widest size for the jaw opening 46, which may be the case as the drill string is being advanced into the ground by the drilling rig 10 during normal drilling operations. FIG. 5C also illustrates the jaws 32a, 32b in the open position. To disconnect a joint between two drill pipes 166 of the drill string, the joint is positioned between the upper and lower breakout wrenches 22. The jaws 32a, 32b of the breakout wrench 22 (upper and lower) are then actuated via respective actuators 28 to close the jaws 32a, 32b around the drill pipe 166, as indicated by directional arrows A3. In particular, the jaws 32a, 32b are moved in a direction generally perpendicular to the drill axis A1 to engage the drill pipe 166 on either side, as shown in FIGS. 5B and 5D. Stated another way, the jaws 32a, 32b move in parallel during operation of the breakout wrench 22. When positioned as shown in FIGS. 5B and 5D, the upper breakout wrench 22 may then be rotated to break the connection between the two drill pipes 166.

FIGS. 5B and 5D illustrate the jaws 32a, 32b in a clamped position, where each jaw 32a, 32b is in a contact with the drill pipe 166 to grasp the drill pipe 166 between the jaws 32a, 32b. Specifically, each jaw 32a, 32b engages the drill pipe 166 at two separate contact locations 180a, 180b, 182a, 182b about the circumference of the drill pipe 166. In that regard, the pair of jaws 32a, 32b engage the drill pipe 166 at four separate contact locations 180a, 180b, 182a, 182b about the circumference of the drill pipe 166. The first contact location 180a, 180b between each jaw 32a, 32b and the drill pipe 166 is between the grip surface 40 of the male jaw block 36 and the drill pipe 166. The first contact locations 180a, 180b may be between the finger 88 of the male jaw block 36 and the drill pipe 166. The second contact location 182a, 182b between each jaw 32a, 32b and the drill pipe 166 is between the grip surface 42 of the female jaw block 38 and the drill pipe 166. The second contact location 182a, 182b may be between the arms 132 of the female jaw block 38 and the drill pipe 166. As shown, the wide jaw block angle 63 of each jaw 32a, 32b results in the contact locations 180a, 180b, 182a, 182b for each jaw 32a, 32b being spaced far enough apart such that all four contact locations 180a, 180b, 182a, 182b are substantially evenly spaced about the circumference of the drill pipe 166. Maintaining sufficient spacing between the contact locations 180a, 180b, 182a, 182b between the jaws 32a, 32b and the drill pipe 166, such as approximately even spacing, reduces the risk of deformation or “egging” of the drill pipe 166 when clamped between the jaws 32a, 32b.

As described above, different drill pipe diameters may be required for drilling operations. In that regard, FIGS. 6A-6C illustrate a small diameter drill pipe 168 being used for drilling, such as a 3.5 inch drill rod. Notably, the diameter of the drill pipe 168 is smaller compared to the drill pipe 166 of FIGS. 5A-5D. Referring now to FIG. 6A, the drill pipe 168 is arranged between the first arm 170 and the second arm 172 of the breakout wrench 22, generally coaxial with the drill axis A1, such that the pair of jaws 32a, 32b are diametrically opposed about the circumference of the drill pipe 168. Specifically, the drill pipe 168 is located within the jaw opening 46 between the pair of jaws 32a, 32b, which are in the open position. The jaws 32a, 32b of the breakout wrench 22 (upper and lower) may then be actuated to engage the drill string to disconnect a joint between two drill pipes 168, as described above. In that regard, respective actuators 28 close the jaws 32a, 32b around the drill pipe 168, as indicated by directional arrows A4. Again, the jaws 32a, 32b are moved in parallel, and in a direction generally perpendicular to the drill axis A1, to engage the drill pipe 168 on either side, as shown in FIGS. 6B and 6C. When so positioned, the upper breakout wrench 22 may then be rotated to break the connection between the two drill pipes 168.

FIGS. 6B and 6C illustrate the jaws 32a, 32b in the clamped position, where each jaw 32a, 32b is in a contact with the drill pipe 168 to grasp the drill pipe 168 between the jaws 32a, 32b. Due to the small diameter of the drill pipe 168, the jaws 32a, 32b fit together (interlock or mesh) about the drill pipe 168 to engage the drill pipe 168 at four separate contact locations 184a, 184b 186a, 186b, as shown. As the jaws 32a, 32b are moved together, the female jaw block 38 of the first jaw 32a is received by the male jaw block 36 of the second jaw 32b, and the female jaw block 38 of the second jaw 32b is received by the male jaw block 36 of the first jaw 32a to allow the jaws 32a, 32b to close about the drill pipe 168. Where the jaws 32a, 32b would have otherwise bottomed out, the meshing of the jaws 32a, 32b provides for a small jaw opening 46 and thus the ability for the breakout wrench 22 to grasp a small diameter of drill pipe 168.

The configuration of the male and female jaw blocks 36, 38 permits the meshing of the jaws 32a, 32b, as shown in FIGS. 6B and 6C. Particularly, the first jaw 32a and the second jaw 32b mesh together at two separate locations 188, 190 spaced apart along a length of the first jaw 32a and the second jaw 32b. That is, as the jaws 32a, 32b mesh or fit together, the finger 88 of the male jaw block 36 of the first jaw 32a is received into the slot 126 in the female jaw block 38 of the second jaw 32b to define the first meshing location 188, and the finger 88 of the male jaw block 36 of the second jaw 32b is received into the slot 126 in the female jaw block 38 of the first jaw 32a to define the second meshing location 190. When positioned in this manner, each arm 132 of a female jaw block 38 extends along and overlies a respective sidewall 94 of the finger 88 of a corresponding male jaw block 36. To that end, each finger 88 may be partially or fully received into the corresponding slot 126, depending on the diameter of the drill pipe 168.

When in the clamped position, as shown in FIGS. 6B and 6C, each jaw 32a, 32b engages the drill pipe 168 at two separate contact locations 184a, 184b, 186a, 186b about the circumference of the drill pipe 168, with the pair of jaws 32a, 32b engaging the drill pipe 168 at four separate contact locations 184a, 184b, 186a, 186b about the circumference of the drill pipe 168. The first contact location 184a,184b between each jaw 32a, 32b and the drill pipe 168 is between the grip surface 40 along the body 90 of the male jaw block 36 and the drill pipe 168. The second contact location 186a, 186b between each jaw 32a, 32b and the drill pipe 168 is between the grip surface 42 along the body 134 of the female jaw block 38 and the drill pipe 168. The meshing ability and the wide jaw block angle 63 of each jaw 32a, 32b allows the contact locations 184a, 184, 186a, 186b for each jaw 32a, 32b to be spaced far enough apart such that all four contact locations 184a, 184, 186a, 186b are substantially evenly spaced about the circumference of the drill pipe 168. As described above, maintaining sufficient spacing between the contact locations 184a, 184, 186a, 186b between the jaws 32a, 32b and the drill pipe 168, such as approximately even spacing, reduces the risk of deformation or “egging” of the drill pipe 168 when clamped between the jaws 32a, 32b. Thus, the jaws 32a, 32b provide the breakout wrench 22 with the ability to grasp a range of drill pipe diameter while also minimizing the risk of deformation or “egging” of the drill pipe.

While the present invention has been illustrated by the description of various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Thus, the various features discussed herein may be used alone or in any combination. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.