WATER WELL TOP HEAD DRILL ADAPTER

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S. C § 119(e) to U.S. Provisional Ser. No. 63/734,991 , filed Dec. 17, 2024, the disclosure of this prior application is considered part of this application and is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to an adapter for a top head drilling rig that provides vertical movement to a water well plunger.

BACKGROUND

Top head drills are well known and widely used to drill water wells and for the use of other in-ground drilling. More particularly, it is well known to use a hydraulic system to drive a rotary top head drill mounted on a truck to drill a well. Once drilled in this manner and lined with a casing and bottom well screen, a well is typically developed by injecting water and compressed air into the well to lift the water. However, this can cause an undesired amount of debris, such as silt and drilling clay, to clog the sand grains and well screen, which can reduce the efficiency of the well. Alternatively, when developing a well by using the rig's hydraulic system to vertically move the drill head and a plunger mounted to the drill reciprocally a short distance up and down to develop a well, the vertical hydraulics are frequently taxed and overheat, damaging the hydraulic system. It would be beneficial to provide a system that provides vertical movement to a plunger without vertically articulating the drill head in order to develop water wells.

SUMMARY

The disclosure provides a top head drill adapter configured to develop a water well with the use of a top head drilling unit. The adapter may include a top shaft, a plurality of gears in a right angle gear box, a pair of linkage arms, and a bottom shaft. The top shaft may be threadably engaged with a drilling head of the top head drilling unit and configured to rotate with the drilling head. The plurality of gears may be driven by rotation of the top shaft. The pair of linkage arms may be coupled with the right angle gear box. The bottom shaft may be connected to the pair of linkage arms. Rotation of the plurality of gears may provide reciprocating vertical motion to the pair of linkage arms and the bottom shaft. The bottom shaft may be configured to connect to a drill pipe assembly, such as a one or more pipe sections and a plunger, for developing a well.

In some examples, the plurality of gears include an input gear coupled to the top shaft, such that rotation of the top shaft imparts rotation to the input gear. The input gear may rotate around the same vertical axis as the input shaft and the drilling head. The plurality of gears may also include a first output gear and a second output gear each configured to be engaged by the input gear. The output gears may be positioned perpendicularly to the input gear on a first side and a second side, opposite the first side, of the input gear. The first output gear may be coupled to a first output shaft, which extends out of a first side of the right angle gear box. The second output gear may be coupled to the second output shaft, which extends out of a second side of the right angle gear box, opposite the first side. The first output shaft may extend to and be coupled to a first linkage arm of the pair of linkage arms. The second output shaft may extend to and be coupled to a second linkage arm of the pair of linkage arms.

Each of the pair of linkage arms, in some examples, include a crank element and an articulating link element. The crank element may be coupled at a first end to one of the output shafts at a crank pin such that the crank element is able to rotate about the horizontal axis of the output shaft. The crank element may be coupled at a second end to the articulating link element at a pivot joint. The articulating link element may be coupled at a second end to a support of the bottom shaft via a fixed connection.

In additional examples, the support is a horizontal beam extending between the second end of the articulating link element of the first pair of linkage arms and the second end of the articulating link element of the second pair of linkage arms. The support may move in an upward and downward direction with the second end of the articulating link elements. The bottom shaft may extend from the support perpendicularly in a central portion of the support, such that the bottom shaft is in an axial alignment with the top shaft. The bottom shaft may be configured to mate with a drill pipe assembly, for example, via a threaded connection.

Also, according to the disclosure, a method of drilling includes providing a top head drill with an adapter, inputting a rotational movement into a top shaft of the adapter, driving a gear from the rotational movement that operates a pair of linkage arms, and providing a reciprocating vertical movement to a plunger from the linkage arms. The method may further include engaging a threaded connection of the top shaft with a reciprocating threaded connection of the top head drill to connect the adapter to the top head drill. Driving a gear may further include rotating an input gear about a vertical axis via the top shaft, rotating a first output gear and a second output gear which are configured to be engaged by the input gear about a horizontal axis, inputting a rotational movement about the horizontal axis to a first output shaft and a second output shaft, and transferring the rotational movement to a first end of a pair of linkage arms. Providing a reciprocating vertical movement may further include rotating a first end of a crank element of the pair of linkage arms about the horizontal axis, driving a first end of an articulating link element that follows a second end of the crank element, and imparting a vertical movement to a support via a second end the articulating link element, the support provided to include a plunger for drilling. The method may further include rotating the crank element from a retracted position to an extended position, and imparting a downward vertical movement to the plunger. The method may further include rotating the crank element from an extended position to a retracted position, and imparting an upward vertical movement to the plunger.

Also according to the disclosure, a system for imparting a vertical movement to a well pipe assembly may include a top head drilling unit having a drilling head configured to attach to an adapter. The adapter may include a top shaft threadably engaged with the drilling head, a right angle gear box having an input gear, a first output gear, and a second output gear, a pair of linkage arms coupled to the first and second output gears by a first output shaft and a second output shaft, and a support extending between the pair of linkage arms and including a plunger for connecting the drill pipe sections. The input gear may be coupled to the top shaft and driven by rotational movement of the drilling head imparted on the top shaft. The first and second output gears may be configured to be engaged by the input gear. The first output shaft and the second output shaft may impart rotation about a horizontal axis to the pair of linkage arms. The support may be configured to move vertically with the pair of linkage arms. In examples, a first of the pair of linkage arms may include a first crank element coupled to the first output shaft and a first articulating element coupled to a first side of the support. The first crank element and the first articulating element may be coupled at a first joint. A second of the pair of linkage arms may include a second crank element coupled to the second output shaft and a second articulating element coupled to a second side of the support, opposite the first side. The second crank element and the second articulating element may be coupled at a second joint. The first crank element and the second crank element may rotate about the horizontal axis in the same rotational position relative to the horizontal axis.

Each of the above independent aspects of the present disclosure, and those aspects described in the detailed description below, may include any of the features, options, and possibilities set out in the present disclosure and figures, including those under the other independent aspects, and may also include any combination of any of the features, options, and possibilities set out in the present disclosure and figures.

The details of one or more implementations of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, advantages, purposes, and features will be apparent upon review of the following specification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a top head drill mounted on a drilling truck for use with a drill adapter.

FIG. 2 is a front view of a drill adapter in a retracted position.

FIG. 3 is a front view of the drill adapter in an extended position.

FIG. 4 is a side view of the drill adapter in the retracted position.

FIG. 5 is a cross-sectional view of a right angle gear box used with the drill adapter.

FIG. 6 is a flow chart illustrating the method of well drilling with a drill adapter.

Like reference numerals indicate like parts throughout the drawings.

DETAILED DESCRIPTION

Referring now to the drawings and the illustrative embodiments depicted therein, a top head drill adapter 100 is provided for use with a rotary top head drill 102 mounted on a drilling truck 104, as shown in FIGS. 1-5. A drilling truck 104 for developing wells is shown in FIG. 1, although, various other mobile drilling vehicles or rigs may be provided for use with the adapter, such as trailer mounted top head drills, excavator mounted top head drills, among other capable machinery. The drilling truck 104 includes a power source, such as one or more hydraulic pumps, a drill mast 106 pivotally connected to the truck or associated frame structure, and one or more lift mechanisms 108 for tilting the mast 106 between a horizontal stored position and an upright position, as shown in FIG. 1. The lift mechanisms 108 also support the mast 106 in the upright position during operation of the top head drill 102, such as one or more hydraulic linear actuators that operate with the hydraulic system to raise and lower the drill mast 106. The mast 106 includes guide rails or guide surfaces extending along the length and facing rearward on the drill truck when the mast is in the upright position.

As further shown in FIG. 1, a drill head assembly 110 is movably attached to the drill mast 106 with a carriage 114 that is supporting a rotary unit 112 with one or more drive motors, such as hydraulic motors operably connected to the power source on the drilling truck 104. The drill head assembly 110 is movable vertically on the mast via the carriage 114, which may be moved and positioned vertically with operation of an actuator, such as a linear actuator that may be powered with the hydraulics, a hydraulicly powered pulley system, or an electric winch and the like. The rotary unit 112 supported on the carriage 114 of the drill head assembly 110 provides rotational movement to the top head drill 102. During the drilling of a well, the top head drill 102 is threadably attached to a series of drill pipe sections 116 that extend down through a table support 118 and into the ground to engage the rotary drill bit. When drilling is completed and the hole is lined with a casing and a bottom well screen, the drill head assembly 110 is sequentially raised and lowered the full length of the mast 106 to lift and remove at least some of the drill pipe sections and to add a plunger and the reciprocating drill adapter 100, as shown in FIG. 1.

As illustrated in FIGS. 2 and 3, the adapter 100 may include a top shaft 202. The top shaft 202 may be a cylindrical tube and be configured to connect the adapter 100 to a lower end of the drill head 102 (see, FIG. 1). In some examples, the drill head 102 may include a threaded connection 120 that is configured to threadably mate with the top shaft 202. For example, a threaded connection 120 may be located on an outer surface of a lower portion of the drill head 102. The threaded connection 120 may be received in a reciprocating threaded connection on an internal surface of the top shaft 202. In other examples, the adapter may be connected to the drill head through other mechanical connections which allow rotational movement of the drill head to be imparted on the top shaft of the adapter.

The top shaft 202 of the adapter 100 is coupled to a gear box 204. As illustrated in FIG. 5, the gear box 204 may be a right angle gear box. In some examples, the top shaft 202 is coupled to an input gear 206 of the gear box 204. The top shaft 202 is configured to rotate with the drill head 102 such that rotational movement from the drill head 102 is provided to the top shaft 202 and drives the input gear 206 of the right angle gear box 204 to rotate around a vertical axis V. The right angle gear box 204 may include a first output gear 208 and a second output gear 210 which are positioned perpendicular to the input gear along a horizontal axis H and positioned on a first side and a second side of the input gear 206, respectively. The first output gear 208 and the second output gear 210 are positioned to engage the input gear 206 such that rotation of the input gear 206 rotates the output gears 208, 210, transmitting torque and rotation from the top shaft 202 and input gear 206 to the output gears 208, 210 around the horizontal axis H.

Referring again to FIG. 2, the first output gear 208 and the second output gear 210 are coupled to a pair of linkage arms 212A, 212B. The first output gear 208 may be coupled to a first linkage arm 212A via a first output shaft 214. The first output shaft 214 may extend from the first output gear 208, through a first side of the gear box 204, perpendicular to the top shaft 202 and along the horizontal axis H. The second output gear 210 may be coupled to a second linkage arm 212B via a second output shaft 216. The second output shaft 216 may extend from the second output gear 210, through a second side of the gear box 204, perpendicular to the top shaft 202 and along the horizontal axis H. The first output shaft 214 and the second output shaft 216 rotate around the horizontal axis H driven by the first and second output gears 208, 210.

The pair of linkage arms 212A, 212B may each further include a crank element 220A, 220B and an articulating link element 222A, 222B. The crank element 220A, 220B is coupled at an outer end of the output shafts 214, 216 located outside of the gear box 204 and opposite the inner end of the output shafts 214, 216 which is coupled to the output gears 208, 210. For example, a first crank element 220A extends from the outer end of the first output shaft 214 and a second crank element 220B extends from the outer end of the second output shaft 216. The crank elements 220A, 220B may be attached to the first output shaft 214 and the second output shaft 216 via a crank pin 224A, 224B to allow the first crank element 220A and the second crank element 220B to rotate with the first and second output shafts 214, 216. The first crank element 220A and the second crank element 220B are provided in the same rotational position relative to the horizontal axis H as they rotate with the output shafts 214, 216. The crank elements 220A, 220B may include an arm support 218. The arm support 218 may be a piece of sheet metal welded or otherwise connected between each of the crank elements 220A, 220B and the output shafts 214, 216 to provide additional strength and stability to the crank elements 220A, 220B.

The articulating link elements 222A, 222B are configured to attach to a second end of the crank elements 220A, 220B at a pivot joint 226A, 226B. For example, a first end of a first articulating link element 222A is connected to the second end of the first crank element 220A at a first pivot joint 226A, and a first end of a second articulating link element 222B is connected to the second end of the second crank element 222B at a second pivot joint 226B. The first and second pivot joints 226A, 226B may be a mechanical joint such as formed by a threaded bolt and a hex nut. The first and second pivot joints 226A, 226B provide rotation of the second end of the first and second crank elements 220A, 220B around an axis of the pivot joints 226A, 226B. The first and second articulating link elements 222A, 222B remain in the relatively same rotational position relative to the axis of the pivot joints 226A, 226B. As a result, the first and second articulating link elements 222A, 222B follow the second end of the crank elements 220A, 220B at the pivot joints 226A, 226B as the crank elements 220A, 220B rotate about the horizontal axis H.

A second end of each of the first articulating link element 222A and the second articulating link element 222B are connected to a horizontal support 230. The articulating link element 222A, 222B may be connected to the support 230 via a fixed connection 228A, 228B such as via a bolt. The horizontal support 230 extends parallel to the first and second output shafts 214, 216 between the second end of the first and second articulating link elements 222A, 222B. The second end of the first articulating link element 222A is connected to a first side of the support 230 at a first fixed connection 228A. The second end of the second articulating link element 222B is connected to a second side of the support 230, opposite the first side, at a second fixed connection 228B. The first articulating link element 222A and the second articulating link element 222B may be fixedly connected to the support 230 at the fixed connections 228A, 228B such that the support 230 moves with the second end of the articulating link elements 222A, 222B. As a result, the rotation of the output shafts 214, 216 causes reciprocating vertical movement to the support 230 via the movement of the pair of linkage arms 212A, 212B.

The horizontal support 230 includes a cylindrical bottom shaft or plunger 232. The bottom shaft 232 may be axially aligned with the top shaft 202 along a vertical axis V in a central portion of the support 230. The bottom shaft 232 includes a threaded connection 234 configured to connect to tooling for drilling into a surface such as stacked drill pipe sections or a water well plunger. Thus, the rotational motion from operation of the drill head 102 and that is provided to the right angle gear box 204 of the adapter 100 imparts a reciprocating vertical motion to the bottom shaft 232 and the connected pipe sections via the pair of linkage arms 212A, 212B and the horizontal support 230 to provide a pumping motion configured to produce a water well with the mobile drilling unit.

Referring to FIGS. 2 and 3, the pair of linkage arms move between a retracted position 200 (FIG. 2) and an extended position 300 (FIG. 3) to provide a pumping motion for drilling. In the retracted position 200, the crank elements 220A, 220B are in an upward most position of its rotational cycle about the horizontal axis H. The crank elements 220A, 220B are positioned above the plane of the output shafts 214, 216 and generally parallel with the vertical axis V. The first end of the articulating link elements 222A, 222B are connected to the pivot joints 226A, 226B to follow the second end of the crank element 220A, 220B such that the first end of the articulating link elements 222A, 222B are positioned above the plane of the output shafts 214, 216 and generally parallel with the vertical axis V.

In the retracted position 200, the articulating link elements 222A, 222B are in a raised position after following the crank elements 220A, 220B at the pivot joint 226A, 226B to the upward most position of the crank elements 220A, 220B in their rotational cycle. In the retracted position 200, the crank elements 220A, 220B and the articulating link element 222A, 222B partially overlap between the horizontal axis H and the upward most position of the pivot joints 226A, 226B. For example, the crank elements 220A, 220B and the articulating link elements 222A, 222B both extend below the pivot joint 226A, 226B. Following the crank elements 220A, 220B to their upward most position imparts a reciprocating upward vertical motion to the horizontal support 230 and bottom shaft 232, positioning the support 230 and bottom shaft 232 in an upward position. In the upward position, a retracted distance D1 between the horizontal axis H and the axis of the fixed connections 228A, 228B in the support 230 is at its shortest distance. The retracted distance D1 is approximately equal to the length of the articulating link elements 222A, 222B minus the length of the crank element 220A, 220B.

In the extended position 300, the crank elements 220A, 220B are in a downward most position of its rotational cycle about the horizontal axis H. The crank elements are positioned below the plane of the output shafts 214, 216 and are generally parallel with the vertical axis V. The first end of the articulating link elements 222A, 222B are connected to the pivot joints 226A, 226B to follow the second end of the crank elements 220A, 220B such that the first end of the articulating link elements 222A, 222B are positioned below the plane of the output shafts 214, 216 and generally parallel with the vertical axis V.

In the extended position 300, the articulating link elements 222A, 222B are in a lowered position after following the crank elements 220A, 220B at the pivot joints 226A, 226B to the downward most position of the crank elements in their rotational cycle. In the extended position 300, the crank elements 220A, 220B and the articulating link elements 222A, 222B only overlap at the pivot joints 226A, 226B. For example, the crank elements 220A, 220B extends above the pivot joints 226A, 226B and the articulating link elements 222A, 222B extends below the pivot joints 226A, 226B. Following the crank elements 220A, 220B to their downward most position imparts a reciprocating downward vertical motion to the horizontal support 230 and bottom shaft 232, positioning the support 230 and bottom shaft 232 in a downward position. In the downward position, an extended distance D2 between the horizontal axis H and the axis of the fixed connections 228A, 228B in the support 230 is at its longest distance. The extended distance D2 is approximately equal to the length of the articulating link 222A, 222B elements plus the length of the crank elements 220A, 220B.

Referring to FIG. 4, an exemplary embodiment of the adapter 100 is provided from a side view. The adapter 100 may include the top shaft 202 extending through a top plate 402 prior to extending into the gear box 204. The top plate 402 may be connected to a gear box support plate 404 positioned perpendicular to the top plate 402 such that the top plate 402 and the support plate 404 form a corner having an L-shape. The support plate 404 may include an elevation support 406 positioned between the support plate 404 and the gear box 204 to provide a surface supporting the gear box 204 on the support plate 404. On a rear side of the support plate 404, opposite the elevation support 406 and gear box 204, the support plate 404 may include a plurality of wheels 408 configured to support the adapter 100. The plurality of wheels 408 are provided such that the adapter 100 may be positioned on a ground for increased mobility of the adapter 100 when not in use with a drilling unit.

Referring to FIG. 6, a flow chart for drilling with use of the adapter is provided. At 602, a top head drill is provided with an adapter. Providing a top head drill with an adapter may include engaging a threaded connection on the top head drill with a threaded connection of the top shaft of the reciprocating adapter. At 604, power may be provided to the top head drill inputting a rotational movement into the top head drill and the top shaft of the adapter.

At 606, a gear box may be driven from the rotational movement of the input shaft that operates a pair of linkage arms. Operating the pair of linkage arms may result from a plurality of engaging gears and shafts which convert the rotational movement about a vertical axis to rotational movement about a horizontal axis. The top shaft may be attached to an input gear, rotating the input gear about the vertical gear of the input shaft. The input gear may be configured to engage a first output gear and a second output gear which are positioned perpendicularly to the input gear such that they are engaged and rotate about a horizontal axis. The first output gear and the second output gear are provided with a first output shaft and a second output shaft which rotate with the output gears about the horizontal axis. The first output shaft and the second output shaft are then coupled with the pair of linkage arms such that rotational movement from the output shafts are provided to a first end of the linkage arms via a crank pin.

At 608, reciprocating vertical movement is provided to a plunger via the operation of the pair of linkage arms. Each of the pair of linkage arms may include a first arm configured as a crank element and a second arm configured as an articulating link element. A first end of the crank element is rotated about the horizontal axis via the rotation of the output shafts and a crank pin connecting the output shafts and the crank elements. The articulating link elements include a first end connected to the crank element at a pivot joint and a second end connected to a horizontal support. The rotation of the crank element drives the first end of the articulating link element to follow the second end of the crank element at the pivot joint while the crank element rotates about the horizontal axis. Driving the second end of the articulating link element to follow the crank element imparts a vertical movement on the support which is connected to the second end of the articulating link elements. As the crank element is rotated from a retracted position to an extended position, the rotation imparts a downward vertical movement to the horizontal support and a bottom shaft or plunger extending from the horizontal support. As the crank element is rotated from the extended position to the retracted position, rotation imparts an upward vertical movement to the horizontal support and the bottom shaft or plunger.

Thus, according to the disclosure, a top head drill adapter may include a top shaft threadably engaged to rotate with a drilling head, a plurality of gears in a right angle gear box driven by rotation of the top shaft, a pair of linkage arms coupled with the right angle gear box, and a bottom shaft connected to the pair of linkage arms. Rotation of the plurality of gears provides reciprocating vertical motion to the pair of linkage arms and the bottom shaft.

Also according to the disclosure, a method of drilling may include providing a top head drill with an adapter, inputting a rotational movement into a top shaft of the adapter, driving a gear from the rotational movement that operates a pair of linkage arms, and providing a reciprocating vertical movement to a plunger from the linkage arms.

According to the disclosure, a system for imparting a vertical movement to a well drill pipe may include a top head drilling unit having a drilling head configured to attach to an adapter. The adapter may include a top shaft threadably engaged with the drilling head, a right angle gear box having an input gear, a first output gear, and a second output gear, a pair of linkage arms coupled to the first and second output gears by a first output shaft and a second output shaft, and a support extending between the pair of linkage arms and including a plunger for connecting the drill pipe sections. The input gear may be coupled to the top shaft and driven by rotational movement of the drilling head imparted on the top shaft. The first and second output gears may be configured to engaged by the input gear. The first and second output shaft may impart rotational about the horizontal axis to the pair of linkage arms. The support may be configured to move vertically with the pair of linkage arms.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature; may be achieved with the two components and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components; and may be permanent in nature or may be removable or releasable in nature, unless otherwise stated.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Furthermore, the terms “first,” “second,” and the like, as used herein do not denote any order, quantity, or importance, but rather are used to denote element from another.

Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount.

Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” “inboard,” “outboard” and derivatives thereof shall relate to the orientation shown in FIG. 2. However, it is to be understood that various alternative orientations may be provided, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in this specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law. The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described