Horizontal directional drilling operations often use a rotary drill bit to drill a generally horizontal hole in the ground. The rotary drill bit is typically mounted at a distal end of a drill string including a plurality of drill rods (e.g., drill pipes) strung together end-to-end. The drill string transfers thrust and torque from a drive mechanism (e.g., an above-ground drive mechanism) to the rotary drill bit. In this way, the drill string is used to rotate the rotary drill bit about a longitudinal axis of the drill string and is concurrently used to apply thrust in a distal direction to the rotary drill bit. Horizontal directional drilling operations are described in more detail in U.S. Patent Application Publication Nos. US 2017/0044835 and US 2012/0118640, which are assigned to VERMEER MANUFACTURING COMPANY, and the disclosures of which are hereby incorporated by reference in their entireties.
Once the hole is complete, the drill string is pulled back through the hole so that product (e.g., cable, pipe, conduit, etc.) can be installed in the hole. To pull the product through the hole, the rotary drill bit, or at least a portion thereof, is often removed from the drill string to allow for the attachment of a pullback device that can connect with the product to install the product within the hole. However, this process can be time consuming and requires additional tooling to complete the pullback process for installing the product. Therefore, improvements are desired.
The present disclosure relates generally to a pullback device for a rotary drill bit used for horizontal directional drilling operations. In one possible configuration, and by non-limiting example, a pullback device is removably secured to the rotary drill bit without having to remove the drill bit, or any portion thereof, from the drill string.
In one aspect of the present disclosure, a pullback system for installing product in a hole includes a rotary drill bit having a plurality of cutter elements, and a pullback device attachable to the rotary drill bit without disassembling the rotary drill bit or removing the rotary drill bit from a drill string. The pullback device includes a frame member and a plurality of anchor arms. Each anchor arm has a first end coupled to the frame member and a second end. Each anchor arm is configured to extend between adjacent cutter elements of the rotary drill bit. An attachment location can be used to attach product to the pullback device.
In another aspect of the present disclosure, a pullback device includes a frame member and a plurality of anchor arms, Each anchor arm is pivotally connected to the frame member at a first end, and has a second end configured to engage a rotary drill bit and to apply a pullback force to the rotary drill bit. Each anchor arm is configured to extend between adjacent cutter elements of the rotary drill bit and further includes a feature that includes a locking surface between the first end and the second end. The pullback device also includes a locking device insertable through an opening in the frame member. When inserted, the locking device has a first end that surrounds the locking surfaces of the anchor arms such that the plurality of anchor arms cannot pivot with respect to the frame member. The locking device also has a second end that includes an attachment location configured to attach a product to the pullback device.
In yet another aspect, a pullback system for installing product in a hole includes a rotary drill bit having a plurality of cutter cones, and a pullback device attachable to the rotary drill bit without disassembling the rotary drill bit or removing the rotary drill bit from a drill string. The pullback device includes a frame member, three anchor arms equally spaced about the frame member, each anchor arm having a first end pivotally coupled to the frame member and a second end configured to fit in an open gap between a drill bit base and adjacent cutter cones of the rotary drill bit. Each anchor arm has a feature that includes a locking surface between the first end and the second end. The pullback device further includes a locking device insertable through an opening in the frame member. When inserted, the locking device has a first end that surrounds the locking surfaces of the anchor arms such that the plurality of anchor arms cannot pivot with respect to the frame member. The locking device also has a second end that includes an attachment location configured to attach a product to the pullback device.
In another aspect of the present disclosure, a method of installing product in a hole includes using a rotary drill bit having a plurality of cutter cones to drill a hole; after completing the hole such that the rotary drill bit has traveled from a start location to an end location, installing a pullback device to the rotary drill bit at the end location, at least a portion of the pullback device being installed in open gaps between a drill bit base and adjacent cutter cones of the rotary drill bit; attaching a product to the pullback device at the end location; and pulling back the rotary drill bit through the hole from the end location to the start location, and detaching the product from the pullback device at the start location.
In another aspect of the present disclosure, a pullback device includes a frame member; a plurality of anchor arms, each anchor arm pivotally connected to the frame member at a first end, and having a second end that includes a claw configured to engage adjacent cutter cones of a rotary drill bit and to apply a radial pullback force to a rotation axis of each cutter cone, each anchor arm further having a feature that includes a locking surface between the first end and the second end; and a locking device insertable through an opening in the frame member, when inserted, the locking device having a first end that surrounds the locking surface of each anchor arm such that the plurality of anchor arms do not pivot with respect to the frame member, and the locking device having a second end that includes an attachment location configured to attach a product to the pullback device.
In another aspect of the present disclosure, a pullback device includes a frame member having an inner end that includes opposing attachment surfaces, and an outer end that includes an attachment location; and anchor arms, each anchor arm having an inner end configured to couple to an attachment surface of the frame member, and an outer end having an attachment location. In this example, portions of the frame member and the anchor arms are configured to engage adjacent cutter cones of a rotary drill bit, and to at least partially convert a pullback force FPB into a radial pullback force FPBR with respect to a cutter cone rotation axis.
In another aspect of the present disclosure, a pullback device includes a frame member; and a plurality of anchor arms, each anchor arm having a first end coupled to the frame member, and a second end that includes an attachment location. At least a portion of each anchor arm is configured to engage adjacent cutter cones of a rotary drill bit, and to at least partially convert a pullback force FPB into a radial pullback force FPBR with respect to a cutter cone rotation axis. In this example, the attachment locations are configured to attach a product to the pullback device such that the pullback device can pull the product in a hole.
In another aspect of the present disclosure, a system for drilling a hole and then installing product in the hole includes a rotary drill bit including a drill bit base adapted to be connected to the distal end of a drill string, the drill bit base defining a central axis about which the drill bit base is rotated during drilling, the drill bit base including a plurality of cutter cone mounting locations spaced circumferentially about the central axis, the rotary drill bit including cutter cones mounted at the cutter cone mounting locations, the cutter cones being mounted to rotate relative to the drill bit base about cutter cone axes, the cutter cone axes being oriented at oblique journal angles relative to the drill bit central axis, the cutter cones having conical cutting surfaces that encircle the cutter cone axes; a pullback device attachable to the rotary drill bit without disassembling the rotary drill bit or removing the rotary drill bit from the drill string, the pullback device having: a product attachment portion that aligns generally with the drill bit central axis when the pullback device is attached to the rotary drill bit, the product attachment portion being configured for attachment to the product desired to be installed in the hole; and an anchoring portion for securing the product attachment portion to the rotary drill bit, the anchoring portion being captured between the drill bit base and the conical cutting surfaces of the cutter cones when the pullback device is attached to the rotary drill bit.
In another aspect of the present disclosure, a method for pulling back product in a hole drilled by a drill string including a rotary drill bit having a drill bit base adapted to be connected to the distal end of the drill string, the drill bit base defining a central axis about which the drill bit base is rotated during drilling, the drill bit base including a plurality of cutter cone mounting locations spaced circumferentially about the central axis, the rotary drill bit including cutter cones mounted at the cutter cone mounting locations, the cutter cones mounted to rotate relative to the drill bit base about cutter cone axes, the cutter cone axes being oriented at oblique journal angles relative to the central axis, the cutter cones having conical cutting surfaces that encircle the cutter cone axes, the method comprising: pulling back the product by transferring a pullback load through the cutter cones such that the pullback load has first force vectors perpendicular to the cutter cone axes and second force vectors parallel to the cutter cone axes.
In another aspect of the present disclosure, a drill string for drilling and pulling back product in a hole includes a rotary drill bit having a drill bit base adapted to be connected to a distal end of the drill string, the drill bit base defining a central axis about which the drill bit base is rotated during drilling, the drill bit base including a plurality of cutter cone mounting locations spaced circumferentially about the central axis, the rotary drill bit further including cutter cones mounted at the cutter cone mounting locations, the cutter cones being mounted to rotate relative to the drill bit base about cutter cone axes, the cutter cone axes being oriented at oblique journal angles relative to the central axis, the cutter cones having conical cutting surfaces that encircle the cutter cone axes; and a pullback device having means to engage adjacent cutter cones and to convert a pullback force into a radial load on the cutter cone axes.
A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
The following drawings are illustrative of particular embodiments of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not to scale and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.
The present disclosure pertains to a pullback system for installing product in a hole. The pullback system includes a rotary drill bit having a plurality of cutter cones, and a pullback device attachable to the rotary drill bit without disassembling the rotary drill bit or removing the rotary drill bit from a drill string. Additionally, the pullback device does not require any specialized tools to attach to the rotary drill bit. This allows the pullback device to be quickly attached to the rotary drill bit so that product attached to the pullback device can be easily installed in a hole.
In the examples described and depicted herein, the rotary drill bit 12 is a tri-cone drill bit. Tri-cone drill bits are often used for drilling operations in rocky ground conditions. Tri-cone drill bits can be configured in various ways, and thus the description and figures included herein describe just some of the many examples in which the rotary drill bit 12 can be configured for use with the pullback system 10.
The mount 18 can be used to mount the rotary drill bit 12 to the distal end of a drill string that includes a drill head and a plurality of drill rods strung together end-to-end. In the example shown in
The rotary drill bit 12 can be used on various drill rod drilling systems. In a preferred embodiment, the rotary drill bit 12 is used on a dual drill rod drilling system. Dual drill rod drilling systems are typically used for directional drilling, and typically include an inner rod and an outer rod. A typical dual rod drilling system is generally configured to drive into the ground a series of drill rods joined end-to-end to form a drill string. At the end of the drill string is a drill bit (e.g., the rotary drill bit 12). A dual rod drilling system typically includes a first drive mechanism that controls rotation of the drill bit and a second drive mechanism that controls rotation of a steering element.
When a straight hole is drilled with a dual rod drilling system, the first and second drive mechanisms are concurrently operated such that both the drill bit and the steering element are rotated as the drill string is thrust into the ground.
When a directional change is needed, because the steering element is axially misaligned with the drill string, the drive mechanism that controls the steering element is stopped and the drill string is thrust further into the ground while the drive mechanism that controls the drill bit is rotated. This causes the drill bit to deviate from a straight path and follow the direction dictated by the steering element. A dual drill rod drilling system is described in more detail in U.S. patent application Ser. No. 15/967,948, filed May 1, 2018, assigned to VERMEER MANUFACTURING COMPANY, the disclosure of which is hereby incorporated by reference in its entirety.
A pullback device 16 is attachable to the rotary drill bit 12 without disassembling the rotary drill bit 12 or removing the rotary drill bit 12 from the drill string. Additionally, the pullback device 16 does not require any specialized tools to attach to the rotary drill bit 12. This allows the pullback device 16 to be quickly attached to the rotary drill bit 12 during a pullback operation.
A pullback operation generally occurs after the horizontal directional drilling operation is completed. A trench can be dug into the ground at the end of the hole so that product can be attached to the pullback device 16, and the pullback device 16 can be attached to the rotary drill bit 12. Thereafter, the rotary drill bit 12 (and the pullback device 16 and the product attached thereto) is pulled back through the hole. In some examples, a reaming operation is performed when the rotary drill bit 12 is pulled back through the hole for increasing the diameter of the hole. In such examples, the horizontal directional drilling operation drills a pilot hole, and thereafter, one or more additional cutters can be added to the rotary drill bit 12 to increase the diameter of the pilot hole when the rotary drill bit 12 is pulled back through the hole. In some examples, the rotary drill bit 12 is pulled back through the hole without a reaming operation. Once the rotary drill bit 12 is pulled out of the hole, the product can be detached from the pullback device 16, thereby leaving the product installed inside the hole.
The pullback device 16 includes a frame member 20 and a plurality of anchor arms 22. Each anchor arm 22 has a first end 24 coupled to the frame member 20, and a second end 26 configured to engage the cutter cones 14 of the rotary drill bit 12.
The second end 26 of each anchor arm 22 can transfer a pullback force from the pullback device 16 (e.g., in the direction that the pullback device 16 is pulled through the hole) into a radial pullback force with respect to the rotation axis of each cutter cone 14. This can help to prevent the cutter cones 14 from being pulled off of their respective bearings during the pullback operation. The pullback device 16 can also include a product attachment portion 28 that aligns generally with the drill bit central axis 21 when the pullback device 16 is attached to the rotary drill bit 12, the product attachment portion 28 can be attached to the product desired for installation in the hole.
In the example depicted in
The swivel device 30 includes a center component 44 that allows a first half 46 of the swivel device 30 to rotate along with the pullback device 16 (and rotary drill bit 12 attached thereto), while preventing a second half 48 of the swivel device 30 from rotating along with the pullback device 16. Thus, the swivel device 30 can prevent the product from rotating about the central axis 21 of the rotary drill bit 12 inside the hole when the pullback device 16 is pulled back through the hole.
In the example shown in
In some examples, the anchor arms 22 of the pullback device 16 are part of an anchoring portion that can secure the product attachment portion 28 to the rotary drill bit 12. As shown in
In some examples, the number of anchor arms 104 on the pullback device 100 is equal to the number of cutter cones 14 on the rotary drill bit 12. For example,
As shown in
As shown in
In some examples, the pullback device 100 includes a pin 128, and the locking device 118 includes a bore 130 between the first end 122 and the second end 124 of the locking device 118. The pin 128 is insertable in the bore 130 for restraining the locking device 118 within the opening 120 of the frame member 102.
As shown in
In some examples, the locking device 118 is an axial attachment anchor arm that is part of a product attachment portion of the pullback device 100, and that aligns with the central axis of the rotary drill bit 12 when the pullback device 100 is attached to the rotary drill bit 12, and that can be used to couple product to the first, second, and third radial anchor arms 104.
In the example shown in
Due to each cutter cone mounting location 52 defining a cutter cone rotation axes C-C that is oriented at an oblique journal angle relative to the drill bit central axis 21, the drilling force FD includes both an axial drilling force component FDA and a radial drilling force component FDR. During pullback, the claw 110 of each anchor arm 104 engages adjacent cutter cones 14 such that the claw 110 at least partially converts the pullback force FPB into an axial pullback force component FPBA and a radial pullback force component FPBR with respect to each cutter cone rotation axes C-C. Thus, the pullback force FPB is not a pure axial force, but rather the pullback force FPB is a resultant force of the axial pullback force component FPBA and the radial pullback force component FPBR. The resultant pullback force FPB has a larger magnitude than the individual axial pullback force component FPBA and the radial pullback force component FPBR. Thus, the magnitude of the axial pullback force component FPBA (the force vector that would tend to pull the cutter cones 14 off from the drill bit base 17) is less than the magnitude of the pullback force FPB. This is advantageous to prevent the cutter cones 14 from being pulled off of the drill bit base 17 during pullback.
As shown in
The pullback device 200 further includes anchor arms 212. Each anchor arm 212 has an inner end 214 and an outer end 216. The inner end 214 of each anchor arm 212 is configured to couple to an attachment surface 208 of the frame member 202. The outer end 216 of each anchor arm 212 includes an attachment location 210.
In the example pullback device 200, the frame member 202 and the anchor arms 212 are radial portions that are part of an anchoring portion that can secure the pullback device 200 to the rotary drill bit 12. As shown in
As shown in
As shown in
The attachment locations 210 on the frame member 202 and the anchor arms 212 can be part of a product attachment portion that radially aligns with the drill bit central axis when the pullback device 200 is attached to the rotary drill bit 12. The product attachment portion, as defined by the attachment locations 210, can attach desired product to the pullback device 200 such that the pullback device 200 can be used to install the product in a hole when the pullback device 200 is attached to the rotary drill bit 12, and the rotary drill bit 12 is pulled back through the hole.
In the example of
As shown in
The attachment locations 310 on the anchor arms 304 can be part of a product attachment portion that radially aligns with the central axis of the rotary drill bit 12 when the pullback device 300 is attached to the rotary drill bit. The product attachment portion, as defined by the attachment locations 310, can attach desired product to the pullback device 300 such that the pullback device 300 can be used to install the product in a hole when the pullback device 300 is attached to the rotary drill bit 12, and the rotary drill bit 12 is pulled back through the hole. In the example shown in
As shown in
After completing the hole such that the rotary drill bit has traveled from a start location to an end location, the method 700 includes a step 704 of installing a pullback device to the rotary drill bit at the end location, the pullback device being installed in open gaps between a drill bit base and adjacent cutter cones of the rotary drill bit. In some examples, a trench can be dug into the ground at the end location so that the pullback device can be attached to the rotary drill bit at the end location.
In some examples, the step 704 of installing the pullback device to the rotary drill bit can include pivoting a plurality of anchor arms of the pullback device so that each anchor arm fits in a gap between the drill bit base and adjacent cutter cones. In some examples, the step 704 of installing the pullback device to the rotary drill bit can further include inserting a locking device through an opening in a frame member of the pullback device after each anchor arm has been fitted in a gap between the drill bit base and adjacent cutter cones to prevent the anchor arms from pivoting. In some examples, the step 704 of installing the pullback device to the rotary drill bit can further include inserting a pin through a bore in the locking device for restraining the locking device within the opening in the frame member of the pullback device.
The method 700 includes a further step 706 of attaching product to the pullback device at the end location. In some examples, the product can be attached directly to the pullback device. In other examples, the product can be attached to a swivel device (such as the swivel device 30 shown in
Thereafter, the method 700 includes a further step 708 of pulling back the rotary drill bit through the hole from the end location to the start location. In some examples, the rotary drill bit is attached to a distal end of a drill string, and the drill string can be pulled through the hole by a drive mechanism.
Afterwards, the method 700 includes a step 710 of detaching the product from the pullback device at the start location, thereby leaving the product installed in the hole. In some examples, the method 700 further includes detaching the pullback device from the rotary drill bit by removing a pin from a locking device of the pullback device, removing the locking device from a frame member of the pullback device, and pivoting the anchor arms of the pullback device to disengage the cutter cones of the rotary drill bit to remove the pullback device from the rotary drill bit.
As a further example,
The drill string 902 includes multiple drill rod assemblies that are connected to the drilling machine 904 at an up-hole end 908 and a rotary drill bit 910 at a downhole end 912. The drill rod assemblies are strung together end-to-end to form the drill string 902, which can extend significant distances in some drilling applications.
Each drill rod assembly includes an outer tubular drill rod and a smaller, inner drill rod. The inner drill rod fits inside the tubular outer drill rod. The inner drill rod of each drill rod assembly is interconnected to the adjacent inner drill rods.
During a drilling operation, multiple drill rod assemblies can be added to the drill string 902. When coupled, the drilling machine 904 can simultaneously rotate one or both of the outer and inner drill rods of each drill rod assembly. Once the drilling operation is complete, the drill rod assemblies are removed from the drill string 902 during a pullback operation. As shown in
The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims.
This application claims the benefit of U.S. Provisional Patent Application No. 62/721,020 filed Aug. 22, 2018, the entire content of which is hereby incorporated by reference herein.
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