System and method for automatically controlling a pipe handling system for a horizontal boring machine

Information

  • Patent Grant
  • 6179065
  • Patent Number
    6,179,065
  • Date Filed
    Wednesday, September 2, 1998
    26 years ago
  • Date Issued
    Tuesday, January 30, 2001
    23 years ago
Abstract
An automatic pipe handling system for automatically transporting pipe sections to and from a horizontal boring machine. The system comprises a pipe handling assembly, a pipe lubrication assembly, a makeup/breakout assembly, and an automatic control system. The pipe handling assembly stores pipe sections and transports the pipe sections to and from the drill string of a boring machine. As the pipe handling assembly transports a pipe section, the pipe lubrication assembly lubricates the appropriate pipe joints. The makeup/breakout assembly secures the drill string and pipe joints so that pipe sections can be added to or removed from the drill string. A programmed controller automatically operates the pipe handling system and its components by synchronizing the operations of the pipe handling system. The controller sequences and times the operation of each aspect of the pipe handling system during both the boring operation and the backreaming operation.
Description




FIELD OF THE INVENTION




The present invention relates to the field of horizontal underground boring, and in particular to automated pipe handling systems for automatically loading and unloading pipes on a horizontal boring machine.




SUMMARY OF THE INVENTION




The present invention comprises an automated pipe handling system for use with a horizontal boring machine having a drive system, a drill string comprised of a plurality of pipe sections connectable at threaded joints, a spindle comprising a spindle pipe joint for connecting the drill string to the drive system, and a spindle connection area. The automated pipe handling system comprises a makeup/breakout assembly, a pipe handling assembly, a pipe lubrication assembly, a handling assembly control system, a pipe lubrication control system, and a makeup/breakout control system. The makeup/breakout assembly is adapted to secure the drill string and at least one pipe section in the spindle connection area so that the at least one pipe section in the spindle connection area can be connected to and disconnected from the drill string. The makeup/breakout control system automatically operates the makeup/breakout assembly. The pipe handling assembly is adapted to store and transport pipe sections to and from the spindle connection area. The handling assembly control system automatically operates the pipe handling assembly. The pipe lubrication assembly is adapted to apply lubricant to at least one pipe joint. The pipe lubrication control system automatically operates the pipe lubrication assembly.




The present invention is further directed to an automated control system for a pipe handling system comprising a pipe handling assembly, a pipe lubrication assembly, and a makeup/breakout assembly. The automated control system comprises a handling assembly control system, a pipe lubrication control system, and a makeup/breakout control system. The handling assembly control system automatically operates the pipe handling assembly. The pipe lubrication control system automatically operates the pipe lubrication assembly. The makeup/breakout control system automatically operates the makeup/breakout assembly.




Further, the present invention comprises an automated pipe handling system comprising a pipe handling assembly and a handling assembly control system. The pipe handling assembly is adapted to store and transport pipe sections to and from a connection area. The handling assembly control system automatically operates the pipe handling assembly.




In another aspect, the present invention comprises an automated pipe lubrication system for use with a pipe handling system comprising a pipe handling assembly that stores and transports pipe sections having pipe joints, to and from the pipe handling system. The automated pipe lubrication system comprises a pipe lubrication assembly and a pipe lubrication control system. The pipe lubrication assembly is adapted to apply lubricant to at least one pipe joint. The pipe lubrication control system automatically operates the pipe lubrication assembly.




In yet another aspect, the present invention comprises an automated makeup/breakout system for use with a pipe handling system having a pipe handling assembly. The automated makeup/breakout system comprises a makeup/breakout assembly and a makeup/breakout control system. The makeup/breakout assembly is adapted to secure at least one pipe section so that the pipe joints of the at least one pipe section can be connected to or disconnected from at least one other pipe joint. The makeup/breakout control system automatically operates the makeup/breakout assembly.




The present invention further comprises a horizontal boring machine comprising a frame, a drill string, a drive system, and an automated pipe handling system. The drill string comprises a plurality of pipe sections connected at threaded pipe joints. The drive system, attached to the frame, rotates and advances the drill string through the earth. The automated pipe handling system is used to add and retrieve pipe sections to and from the drill string. The automated pipe handling system comprises a pipe handling assembly, a lubrication assembly, a makeup/breakout assembly, and a control system. The pipe handling assembly is adapted to transport pipe sections to and from the boring machine. The pipe lubrication assembly is adapted to apply lubricant to at least one pipe joint. The makeup/breakout assembly is adapted to secure at least one pipe section so that the pipe section can be connected to or disconnected from the drill string. The control system automatically operates the pipe handling system.




In yet another embodiment, the present invention is a method directed to drilling a horizontal borehole. The method comprises driving a boring tool through the earth using a drill string composed of pipe sections and repeatedly adding pipe sections to the drill string until the borehole is completed. The pipe sections are added by automatically delivering pipe sections to the drill string.




Finally, the present invention is directed to a method for pulling a drill string back through the borehole. The method comprises pulling the drill string back through the earth and repeatedly removing the pipe sections from the drill string. The pipe sections are removed by automatically transporting the pipe sections from the drill string.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a side view of a horizontal boring machine with a pipe handling system in accordance with the present invention.





FIG. 2

is a right frontal perspective view of a pipe handling assembly, a makeup/breakout assembly, and a pipe lubrication assembly for use with a horizontal boring machine.





FIG. 3

is an exploded left frontal perspective view of the pipe handling assembly shown in FIG.


2


.





FIG. 4

is a partial sectional end elevational view of the pipe handling assembly of FIG.


3


.





FIG. 5



a


is a fragmented side view of an embodiment of a pipe holding member of the pipe handling assembly of

FIG. 3

, in a closed position.





FIG. 5



b


is a fragmented side view of an embodiment of a pipe holding member of the pipe handling assembly of

FIG. 3

, in a relaxed position.





FIG. 5



c


is a fragmented side view of an embodiment of a pipe holding member of the pipe handling assembly of

FIG. 3

, in an open position.





FIG. 6

is a block diagram of a circuit for controlling a pipe handling assembly in accordance with the present invention.





FIG. 7

is a flow diagram of a version of software for an Add Pipe routine for the pipe handling assembly controller of FIG.


6


.





FIG. 8

is a flow diagram of a version of software for a Remove Pipe routine for the pipe handling assembly controller of FIG.


6


.





FIG. 9

is a flow diagram of a version of software for a Column Selection routine for the pipe handling assembly controller of FIG.


6


.





FIG. 10

is a partially cut-away, partially exploded, perspective view of one preferred embodiment of a makeup/breakout assembly.





FIG. 11

is a block diagram of a circuit for controlling the makeup/breakout assembly of FIG.


10


.





FIG. 12

is a flow diagram of a version of software for a Connect Pipe routine for the connection controller of FIG.


11


.





FIG. 13

is a flow diagram of a version of software for a Disconnect Pipe routine for the connection controller of FIG.


11


.





FIG. 14

is a partially cut-away, perspective view of an alternative embodiment of a makeup/breakout assembly.





FIG. 15

is a flow diagram of an alternative version of software for a Disconnect Pipe routine for the controller of FIG.


11


.





FIG. 16

is an exploded, schematic illustration of a preferred embodiment of a pipe lubrication assembly.





FIG. 17



a


is an exploded, schematic illustration of an alternative embodiment of a pipe lubrication assembly.





FIG. 17



b


is an exploded, partial top view of the pipe lubrication assembly of

FIG. 17



a.







FIG. 18

is a block diagram of a circuit for controlling the pipe lubrication assembly.





FIG. 19

is a flow diagram of a version of software for the lubrication controller of FIG.


18


.





FIG. 20

is an exploded, partially fragmented side elevational view of an alternative embodiment of the pipe lubrication assembly.





FIG. 21

is an exploded end elevational view of the pipe lubrication assembly of FIG.


20


.





FIG. 22

is a schematic illustration of a machine control system in accordance with an embodiment of the present invention.





FIGS. 23-27

illustrate flow diagrams of software for the machine control system of

FIG. 22

during a boring operation.





FIGS. 28-31

illustrate flow diagrams of software for the machine control system of

FIG. 22

during a backreaming operation.





FIG. 32

is a schematic illustration of an alternative embodiment for a circuit for controlling a makeup/breakout assembly.





FIG. 33

is a schematic illustration of an alternative embodiment for a circuit for controlling a pipe handling assembly.











BACKGROUND OF THE INVENTION




Horizontal boring machines are used to install utility services or other products underground. Horizontal boring eliminates surface disruption along the length of the project, except at the entry and exit points, and reduces the likelihood of damaging previously buried products. Skilled and experienced crews have greatly increased the efficiency and accuracy of boring operations. However, there is a continuing need for more automated boring machines which reduce the need for operator intervention and thereby increase the efficiency of boring underground.




The boring operation is a process of using a boring machine to advance a drill string through the earth along a desired path. The boring machine generally comprises a frame, a drive system mounted on the frame and connected to one end of the drill string, and a boring tool connected to the other end of the drill string. The drive system provides thrust and rotation needed to advance the drill string and the boring tool through the earth. The drive system generally has a motor to rotate the drill string and separate motor to push the drill string. The drill string is advanced in a straight line by simultaneously rotating and pushing the drill string through the earth. To control the direction of the borehole, a slant-faced drill bit may be used. When the direction of the borehole must be changed, the drill bit is positioned with the slant-face pointed in the desired direction. The drill string is then pushed through the earth without rotation, so that the slant-face causes the drill string to deflect in the desired direction.




The drill string is generally comprised of a plurality of drill pipe sections joined together at threaded connections. As the boring operation proceeds, the drill string is lengthened by repeatedly adding pipe sections to the drill string. Each time a pipe section is added to the drill string the pipe section being added is aligned with the drill string, the threaded joints are lubricated to ensure proper connections, and the connections between the drive system, the pipe section, and the drill string are secured. The process is the same each time a pipe section is added to the drill string.




When the boring operation is completed, the drill string is pulled back through the borehole, generally with the utility line or product to be installed underground connected to the end of the drill string. Many times, the original borehole must be enlarged to accommodate the product being installed. The enlarging of the borehole is accomplished by adding a backreaming tool between the end of the drill string and the product being pulled through the borehole. During this backreaming operation, pipe sections are removed from the drill string as the drill string gets shorter. Each time a pipe section is taken from the drill string, the connections between the drive system, the pipe section, and the drill string are broken, the pipe section is removed from the boring machine, and the threaded joint of the drill string is lubricated before the drive system is reconnected to the drill string so the backreaming operation can continue. As is the case with the addition of pipe sections to the drill string, the process is repetitive. As one skilled in the art will appreciate, efficient and economic machines for adding and removing pipe sections are a present need in the industry.




DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS




Turning now to the drawings in general and

FIG. 1

in particular, there is shown in

FIG. 1

a horizontal boring machine in accordance with the present invention. The boring machine, designated by reference numeral


10


, generally comprises a frame


14


, a drive system


16


supported on the frame, a pipe handling system


17


supported on the frame, a drill string


18


, and a directional boring tool


20


. The boring machine


10


is operated and monitored with controls located at an operator's console


22


. The operator's console


22


contains a control panel


24


having a display, joystick, and other machine function control mechanisms, such as switches and buttons. From the control panel


24


, each of the underlying functions of the boring machine


10


can be controlled. The display on the control panel


24


may include a digital screen and a plurality of signaling devices, such as gauges, lights, and audible devices, to communicate the status of the operations to the operator.




As depicted in

FIG. 2

, the drive system


16


is connected to the drill string


18


by way of a spindle


26


. The spindle


26


comprises a threaded spindle pipe joint


28


for connection to a threaded pipe joint


30


on the end of a pipe section


32


. As used herein, a pipe joint


30


can be either of the male or female threaded ends of a pipe section


32


. One skilled in the art will appreciate that the drill string


18


is formed of a plurality of individual pipe sections


32


connected together at threaded pipe joints


30


. As designated herein, the reference numeral


32


will refer to individual pipe sections


32


and the reference numeral


18


will refer to the drill string


18


in the earth, where it is understood that the drill string comprises at least one pipe section.




One skilled in the art will also appreciate that the connections between the spindle


26


and an individual pipe section


32


, between the spindle and the end of the drill string


18


, or between the pipe sections comprising the drill string, involve a careful coordination between the rotation and thrust of the spindle. Whenever a connection is made or broken, the rotation and the thrust of the spindle


26


must be coordinated to meet the threaded pitch of the pipe joints


30


and the spindle pipe joint


28


so that the threads of the joints are not damaged. Where connections between joints are discussed in this application, it will be understood that the thrust and rotation of the spindle


26


are being coordinated so as not to damage the joints.




As the boring machine


10


bores the borehole and the drill string


18


is lengthened, additional pipe sections


32


are added or “made up.” The makeup operation begins with the spindle


26


at the back end


33


of a spindle connection area


34


, remote from the exposed end of the drill string


18


. A pipe section


32


is transported to the spindle connection area


34


by a pipe handling assembly


36


. As the pipe section


32


is transported, and before the pipe section is connected to the drill string


18


, the pipe lubrication assembly


38


lubricates pipe joints


30


to ensure proper connections are made. A makeup/breakout assembly


40


then secures the pipe section and the drill string


18


so that the spindle


26


can be connected to the pipe section and the pipe section can be connected to the drill string. The boring operation can then continue by advancing the drill string


18


along the desired path.




When the boring operation is complete, the backreaming operation is started to enlarge the borehole. At the same time, a utility line or other product to be installed underground can be attached to the end of the drill string


18


and pulled back through the borehole. During the backreaming operation, pipe sections


32


are removed from the drill string


18


or “broken out.” When the spindle


26


has moved to the back end


33


of the spindle connection area


34


, the pipe section


32


in the spindle connection area is removed from the drill string


18


. The makeup/breakout assembly


40


secures the pipe section


32


and the drill string


18


in order to disconnect the spindle


26


from the pipe section


32


in the spindle connection area


34


and the pipe section from the drill string


18


. The pipe section


32


, free from the drill string


18


and the spindle


26


, is then transported out of the spindle connection area


34


by the pipe handling assembly


36


. The spindle


26


is then moved to the front end of the spindle connection area


34


. The spindle pipe joint


28


or pipe joint


30


on the exposed end of the drill string is then lubricated so the spindle


26


can be reconnected to the drill string


18


. The backreaming operation can then continue by pulling the drill string


18


back through the borehole.




Traditionally, the makeup and breakout operations have been performed by the operator, with the assistance of wrenches on the boring machine


10


and by manually applying lubricant when needed. One advantage of the present invention is that it provides an apparatus to automatically perform the underlying functions of the makeup and breakout operations.




Pipe Handling System




A preferred embodiment for the pipe handling assembly


36


of the present invention is shown in more detail in

FIGS. 3 and 4

. Pipe handling assemblies suitable for use with the present invention are described in U.S. patent application Ser. No. 08/624,240, filed by the Charles Machine Works, Inc. on Mar. 29, 1996, entitled Pipe Handling Device, the contents of which are incorporated herein by reference.




The pipe handling assembly


36


shown in

FIGS. 3 and 4

shuttles pipe sections


32


between a storage position and the spindle connection area


34


(see FIG.


1


). The pipe handling assembly


36


is preferably attached to the frame


14


of the boring machine


10


or positioned proximate the frame for storing and transporting pipe sections


32


to and from the drill string


18


. The pipe handling assembly


36


comprises a magazine


42


for storing the pipe sections


32


, a pipe return assembly


43


for lifting pipe sections in and out of the magazine, and a transport assembly


44


for transporting pipe sections between the magazine and the spindle connection area


34


.




The magazine


42


defines an open bottom


46


and a plurality of pipe receiving columns


48


. This configuration accommodates a plurality of pipe sections


32


which may be stacked in generally horizontal columns


48


and which may be dispensed or replaced through the open bottom


46


of the magazine


42


. As described fully in U.S. patent application Ser. No. 08/624,240, the magazine


42


is also designed to be removed from the pipe handling assembly


36


so that another magazine with additional pipe sections


32


can be provided to the boring machine


10


during the boring operation. Similarly, an empty magazine


42


can be provided during the backreaming operation for storage of pipe sections


32


removed from the drill string


18


.




The pipe return assembly


43


(

FIG. 3

) is positioned beneath the open bottom


46


of the magazine


42


. As described in U.S. patent application Ser. No. 08/624,240, the pipe return assembly


43


comprises return arms


49


for lowering pipe sections


32


from the magazine


42


and lifting pipe sections back into the magazine.




The transport assembly


44


is situated beneath the open bottom


46


of the magazine


42


. The transport assembly


44


comprises a transport member


50


movably supported on an assembly frame


51


and a drive assembly


52


for driving the movement of the transport member. The drive assembly


52


serves to move the transport member


50


from a receiving position beneath the magazine


42


to an extended position at the spindle connection area


34


. In the preferred embodiment, the drive assembly


52


comprises a hydraulically actuated rack and pinion gear


54


. One skilled in the art will appreciate that other implementations of the drive assembly


52


are possible. For example, a hydraulic cylinder could be used to move the transport member


50


.




The transport member


50


comprises a plurality of shuttle arms


55


and a plurality of pipe holding members


56


. The pipe holding members


56


are adapted to receive and support a pipe section


32


. In a preferred embodiment, a pipe holding member


56


is formed in each of the shuttle arms


55


. One skilled in the art will appreciate that the pipe holding members


56


need not be formed in the shuttle arms


55


but could comprise a separate structure attached to the end of each of the shuttle arms. Each pipe holding member


56


further comprises a gripper device


58


for retaining and stabilizing a pipe section


32


in the pipe holding member.




In one embodiment, shown in

FIG. 4

, the gripper device


58


is a passive device that will engage a pipe section


32


resting in the pipe holding member


56


. The gripper device


58


defines an upper concave surface


59


for receiving the pipe section


32


and is mounted to the shuttle arm


55


by a pivot pin


60


, about which the gripper device is permitted to rotate. A spring


61


, connected between the shuttle arm


55


and the gripper device


58


, provides a rotational force to the gripper device such that the gripper device is maintained in a position to support the pipe section


32


.




When the holding member


56


is receiving a pipe section


32


from one of the pipe receiving columns


48


, the holding member is potentially subject to the cumulative weight of a plurality of pipe sections in the receiving column. The rotational force generated by the spring


61


may be overcome by the cumulative weight and could cause the plurality of pipe sections


32


to spill out of the magazine


42


. To prevent this, the assembly frame


51


has a top surface


62


that extends beneath each of the receiving columns


48


. Consequently, when the pipe holding member


56


receives a pipe section


32


and the rotational force of the spring


61


is overcome by the cumulative weight of a plurality of pipe sections in a receiving column


48


, a bottom surface


63


of the gripper device


58


contacts the top surface


62


of the assembly frame


51


, effectively limiting the rotation of the gripper device and preventing the pipe sections from spilling out of the receiving column.




The ability of the gripper device


58


to rotate also allows the gripper device to passively grip and release a pipe section


32


in the spindle connection area


34


. As the pipe holding member


56


approaches a pipe section


32


in the spindle connection area


34


, the gripper device


58


is urged down and under the pipe section as the pipe section contacts the inclined leading edge


64


of the gripper device. Conversely, as the pipe holding member


56


is pulled away from the pipe section


32


in the spindle connection area


34


, the pipe section is forced against the gripper device


58


and causes a rotational force about the pivot pin


60


sufficient to overcome the supporting force generated by the spring


61


. Thus, the gripper device


58


is forced down and under the pipe section


32


in the spindle connection area


34


, effectively releasing the pipe section.




The gripper device


58


also comprises a contact wheel


65


rotatably mounted on the pivot pin


60


. The pipe section


32


in the pipe holding member


56


rests on the circumferential perimeter of the contact wheel


65


. The rotating contact wheel


65


permits the pipe section


32


to rotate more easily as it rests in the pipe holding member


56


; yet the contact wheel resists axial movement of the pipe section. Preferably, the contact wheel


65


is made of a resilient material such as polyurethane.




The pipe section


32


in the pipe holding member


56


is also contacted by a resistant thumb


66


positioned on the outer edge of the pipe holding member. The resistant thumb


66


has a slightly concave surface more sharply defined at the upper edge of the resistant thumb that engages the pipe section


32


. Preferably, the resistant thumb


66


is made of a resilient material such as polyurethane. The shape of the resistant thumb


66


and the proximity of its upper edge relative to the pivot pin


60


have the effect of providing little resistance to the rotation of the pipe section


32


as it is rotated in direction A. However, as the pipe section


32


is rotated in direction B, it contacts the resistant thumb


62


and attempts to rotate the gripper device


58


about the pivot pin


60


. The slight rotation of the gripper device


58


causes an even tighter gripping action which resists the rotation of the pipe section


32


, effectively gripping the pipe section.




In an alternative embodiment, depicted in

FIGS. 5



a


-


5




c


, the gripper device


58




a


is an active device and comprises a hydraulically actuated pivot arm


67


. The pivot arm


67


is connected by a pivot arm pin


68


or other like mechanism to the end of the pipe holding member


56


. A hydraulic cylinder


69


is connected to the pivot arm


67


such that the pivot arm can be pivoted about the pivot arm pin


68


between a first position (shown in

FIG. 5



a


), a second position (shown in

FIG. 5



b


), and a third position (shown in

FIG. 5



c


). To the end of the pivot arm


67


remote from the pipe holding member


56


is attached a concave shaped grip


70


which is designed to engage the pipe section


32


in the pipe holding member when the pivot arm is fully closed in the first position as shown in

FIG. 5



a


. When the grip


70


engages the pipe section


32


, sufficient resistance is provided to prevent free rotation and free axial movement of the pipe section. In the second position, shown in

FIG. 5



b


, the pivot arm


67


is in a relaxed position. In the relaxed position, the pipe section


32


will rest in the pipe holding member


56


and be permitted to rotate and slide in the pipe holding member. When the pivot arm


67


is in the third position, shown in

FIG. 5



c


, the pivot arm is open and the grip


70


does not engage or retain the pipe section


32


in the pipe holding member


56


.




The present invention also provides for the automated control of the pipe handling assembly


36


by a handling assembly control system, shown in FIG.


6


. The handling assembly control system


72


controls all of the underlying functions of the pipe handling assembly


36


and sequences those operations. The handling assembly control system


72


comprises a handling system sensor assembly


73


and a handling assembly controller


76


. The handling system sensor assembly


73


comprises a spindle position sensor


74


, a spindle torque sensor


75


, and a holding member position sensor


77


.




The spindle position sensor


74


tracks the position of the spindle


26


by monitoring the motor used to thrust the drill string


18


through the earth. The operation of the thrust motor can be correlated to the movement of the spindle


26


in the spindle connection area


34


. Using a speed pickup sensor, for example, magnetic pulses from the motor can be counted and the direction and distance the spindle


26


has traveled can be calculated. An additional sensor or switch can be used to indicate when the spindle


26


has passed a “home” position. The magnetic pulses counted from the motor can then be used to determine how far the spindle


26


has traveled from the home position. When the spindle position sensor


74


detects the position of the spindle


26


at the back end


33


of the spindle connection area


34


, it transmits a


SPINDLE POSITION


signal to the handling assembly controller


76


. In response to the


SPINDLE POSITION


signal, the handling assembly controller


76


operates the pipe handling assembly


36


. One skilled in the art will appreciate other methods for tracking the spindle


26


are also possible, such as photoelectric devices, mechanical devices, resistive devices, encoders, and linear displacement transducers that can detect when the spindle is in a particular position.




The spindle torque sensor


75


detects the pressure in the motor that provides rotation to the drill string


18


and transmits a


SPINDLE CONNECTION


signal. A pressure transducer on the rotation motor that rotates the spindle


26


is used in calculating the torque output from the rotation motor. The amount of torque measured from the rotation motor is an indication of whether the spindle


26


is connected to the drill string


18


and experiencing resistance, or disconnected and rotating freely. In response to the


SPINDLE CONNECTION


signal, the handling assembly controller


76


operates the pipe handling assembly


36


.




The holding member position sensor


77


detects the position of the pipe holding members


56


(see

FIG. 4

) by correlating the operation of the drive assembly


52


to the distance traveled by the pipe holding members


56


. A speed pickup sensor on the motor of the drive assembly


52


is used to count magnetic pulses from the motor. An additional sensor or switch can be used to indicate when the shuttle arms


55


have passed a “home” position. The pulse count is correlated to the distance the shuttle arms


55


, and consequently the pipe holding members


56


, have traveled from the home position. The holding member position sensor


77


transmits a


HOLDING MEMBER POSITION


signal when the pipe holding members


56


are beneath each of the columns


48


of the magazine


42


. The handling assembly controller


76


receives the


HOLDING MEMBER POSITION


signal and causes the pipe holding members


56


to stop beneath the appropriate column


48


. Other ways for detecting the position of the pipe holding members


56


are contemplated. For example, photoelectric devices, mechanical devices, resistive devices, encoders, and linear displacement transducers may be used to indicate when the pipe holding members


56


are beneath a particular column


48


.




The flow chart of

FIG. 7

depicts an example of logic followed by the handling assembly controller


76


during the boring operation when a pipe section


32


is added to the drill string


18


. With reference to

FIGS. 3-5

and


7


, the handling assembly controller


76


will first direct a pipe section


32


be placed in the pipe holding member


56


. If an active gripper device


58




a


is used, the handling assembly controller


76


will relax the gripper device


58




a


at


702


. The return arms


49


then are lowered to place a pipe section


32


in the pipe holding member


56


at


704


. At


706


, the active gripper device


58




a


is closed to secure the pipe section


32


in the pipe holding member


56


. The routine then waits at


708


for a


SPINDLE POSITION


signal indicating the spindle


26


is positioned at the back end


33


of the spindle connection area. When the


SPINDLE POSITION


signal is received, the handling assembly controller


76


causes the shuttle arms


55


to extend at


710


to a position where pipe joints


30


can be lubricated. When the shuttle arms


55


reach the lubrication point at


712


, the handling assembly controller


76


causes the shuttle arms to pause for two seconds to allow lubricant to be applied to pipe joints


30


at


714


. One skilled in the art will appreciate that the two second delay is only exemplary and that any time sufficient to allow the pipe joints to be lubricated may be used. Furthermore, if no lubrication is required, or if the shuttle arms


55


need not pause for lubricant to be applied, then the logic followed by the handling assembly controller could be modified accordingly.




The shuttle arms


55


are fully extended to the spindle connection area


34


at


716


. When the shuttle arms


55


reach the spindle connection


34


area at


718


, the handling assembly controller


76


will slightly relax the active gripper device


58




a


at


720


. The routine then waits at


722


for a


SPINDLE CONNECTION


signal indicating that the pipe section


32


is connected to the drill string


18


. After receiving the


SPINDLE CONNECTION


signal, the handling assembly controller


76


opens the active grippers


58




a


at


724


. The return arms


49


are then lifted at


726


, and the shuttle arms


55


are retracted to their position beneath the magazine


42


at


728


. The


ADD PIPE


routine of

FIG. 7

completes at


730


.




The flow chart of

FIG. 8

illustrates an example of logic for the handling system controller


76


during the backreaming operation when a pipe section


32


is removed from the drill string


18


. The handling system controller


76


initially waits for a


SPINDLE POSITION


signal indicating the spindle


26


is positioned at the back end


33


of the spindle connection area


34


. When the


SPINDLE POSITION


signal is received at


802


, the handling assembly controller


76


will relax the gripper device


58




a


(

FIG. 5

) at


804


, if an active gripper device is used. The return arms


49


are raised at


806


to remove any pipe section


32


that may have been resting in the pipe holding member


56


. The gripper device


58




a


is opened at


808


, and the shuttle arms


55


are fully extended to the spindle connection area


34


at


810


.




When the shuttle arms


55


reach the spindle connection area


34


at


812


, the handling assembly controller


76


puts the gripper device


58




a


in the relaxed position at


814


. The routine then waits for the spindle position sensor


74


to transmit the


SPINDLE POSITION


signal at


816


. The receipt of the


SPINDLE POSITION


signal at this point indicates that the pipe section


32


has been disconnected from the drill string


18


and positioned in the spindle connection area


34


so that the pipe section is aligned with the magazine


42


. The handling assembly controller


76


then fully closes the gripper device


58




a


at


818


. The return arms


49


are lowered at


820


, and the shuttle arms


55


with the pipe section


32


in the pipe holding member


56


are returned to the magazine


42


at


822


. When the pipe holding member


56


is beneath the proper column


48


at


824


, the backreaming operation can continue at


826


.




When the shuttle arms


55


are retracted to the magazine


42


, in either the boring operation or the backreaming operation, the pipe holding member


56


must be positioned below the proper column


48


of pipe in order to receive or replace a pipe section


32


. The flow chart of

FIG. 9

illustrates how the handling assembly controller


76


determines under which column


48


of pipe to position the pipe holding member


56


.




The handling assembly controller


76


accesses information needed for tracking the number of pipe sections


32


in the magazine


42


being used at


902


. The information consists of the number of pipe sections


32


the magazine


42


can hold, the number of columns


48


in the magazine, and the number of pipe sections remaining in the magazine. A check is made at


904


to determine if a pipe section


32


is being removed from the magazine


42


during the boring operation or if a pipe section is being replaced in the magazine during the backreaming operation. If a pipe section


32


is being removed, the pipe count of the appropriate column


48


is decremented at


906


. At


908


a check is made to determine if the magazine


42


is empty. If the magazine


42


is empty, the operator is alerted at


910


that a new magazine is needed. Otherwise, at


912


the procedure returns information indicating which is the appropriate column


48


for receiving the next pipe section


32


.




If a pipe section


32


is being added to the magazine


42


during the backreaming operation, the pipe count of the appropriate column is incremented at


916


. At


918


a check is made to determine if the magazine


42


is full. If the magazine


42


is full, the operator is alerted at


920


that a new magazine is needed. Otherwise, at


922


the procedure returns information indicating which is the appropriate column


48


for returning the next pipe section


32


. One skilled in the art will appreciate that other methods for properly selecting a column


48


in the magazine


42


may be used. For example, switches or photoelectric devices can be used to detect the presence or absence of pipe sections


32


in the magazine


42


; and mechanical stops (either passively or actively positioned) could be used to stop the shuttle arms


55


under the appropriate column


48


.




Makeup/Breakout System




The preferred embodiment for the makeup/breakout assembly


40


is shown in detail in FIG.


10


. The makeup/breakout assembly


40


comprises a plurality of wrenches for holding the drill string


18


and the pipe section


32


in the spindle connection area


34


. In the preferred embodiment, the wrenches are used with a drill string


18


comprised of pipe sections


32


having opposed flats


78


formed on the ends of the pipe sections.




A first wrench


80


secures the drill string


18


. The first wrench


80


defines a keyhole opening


82


having a circular portion


84


slightly larger in diameter than the pipe section


32


. The size of the circular portion


84


of the keyhole opening


82


permits a pipe section


32


to pass unobstructed through the circular portion when the first wrench


80


is in a first position. Consequently, when the first wrench


80


is in the first position, the pipe section


32


passing through the keyhole opening


82


can rotate freely.




The keyhole opening


82


is further characterized by a slot


86


extending from the circular opening


84


. The flat inner sides of the slot


86


are defined by a pair of opposing surfaces


88


positioned to engage the flats


78


of the pipe section


32


when the first wrench


80


is in a second position. In the second position, the first wrench


80


is engaged, locking the pipe section


32


in place and preventing it from rotating.




The movement of the first wrench


80


between the first position and the second position is actuated by a hydraulic cylinder


90


in conjunction with a spring


92


. As the hydraulic cylinder


90


is extended, the first wrench


80


is urged from the first position to the second position. However, because of the keyhole design of first wrench


80


, the first wrench can only move to the second position if the pipe section


32


is aligned so that the flats


78


will engage the opposing surfaces


88


of the first wrench. As the hydraulic cylinder


90


extends, if the pipe flats


78


are not aligned with the opposing surfaces


88


, then the spring


92


will compress. When the flats


78


are aligned, the spring


92


will expand, forcing the first wrench


80


to engage the drill string


18


.




The keyhole design of the first wrench


80


provides added strength to the tool because it fully encompasses the circumference of the drill string


18


. However, one skilled in the art will appreciate other configurations for the first wrench


80


are possible. For example, a forked tool with tines that engage the flats


78


on the pipe section


32


, as described subsequently, could be used to secure the drill string


18


.




The makeup/breakout assembly


40


further comprises a second wrench


94


positioned to secure the pipe section


32


in the spindle connection area


34


. The second wrench


94


is a forked tool having two tines


96


. The width of the tines


96


is slightly more than the width of the flats


78


on the pipe section


32


. The second wrench


94


is designed to be moved between a first position and a second position. In the second position, the second wrench


94


grips the pipe section


32


when the tines


96


engage the flats


78


, preventing the pipe section


32


from rotating with the spindle


26


.




The movement of the second wrench


94


is actuated by a hydraulic cylinder


98


in combination with a spring


100


. As with the first wrench


80


, the second wrench


94


is urged from the first position to the second position by the hydraulic cylinder


98


. However, if the pipe section


32


in the spindle connection area


34


is not aligned so that the flats


78


will engage the tines


96


, the spring


100


will compress. When the flats


78


are aligned, the spring


100


will expand, forcing the second wrench


94


to engage the pipe section


32


in the spindle connection area


34


.




The makeup/breakout assembly


40


further comprises a slidable collar wrench


102


. A collar wrench suitable for use with the present invention is described in detail in U.S. Pat. No. 5,544,712, entitled Drill Pipe Breakout Device, issued Aug. 13, 1996, the contents of which are incorporated herein by reference. The collar wrench


102


has a through-bore permitting the collar wrench to be slid over the front of the spindle


26


and to rotate with the spindle. As the collar wrench


102


is slid over the spindle


26


, inwardly facing surfaces


104


on the collar wrench engage the flats


78


of the pipe section


32


in the spindle connection area


34


.




The movement of the collar wrench


102


is actuated by a hydraulic cylinder


105


in combination with a spring


106


. The collar wrench


102


is moved from the disengaged position to the engaged position by a hydraulic cylinder


105


. However, if the pipe section


32


in the spindle connection area


34


is not aligned with the spindle


26


so that the pipe flats


78


will engage the inwardly facing surfaces


104


of the collar wrench


102


, the spring


106


will compress. When the pipe flats


78


are aligned, the spring


106


will expand, forcing the collar wrench


102


to engage the pipe section


32


in the spindle connection area


34


. Having the collar wrench


102


in the engaged position permits the spindle


26


to be locked to the pipe section


32


so that the pipe section can rotate with the spindle when the threaded connection between the spindle and pipe section has been broken.




One skilled in the art will appreciate that other designs for the wrenches are contemplated. For example, other geometric shapes capable of transmitting torque would be appropriate for the spindle collar wrench. Any number of flats on the end of the pipe section


32


could be configured to engage a corresponding number of surfaces on the inside of the spindle collar wrench


102


, thereby locking the spindle


26


to the pipe section in the spindle connection area


34


. Similarly, the first wrench


80


and the second wrench


94


could be designed to have a corresponding number of surfaces that would engage the arrangement of flats on the end of the pipe sections


32


. The wrenches could be maneuvered to engage the flats, effectively clamping the pipe section


32


and the drill string


18


to prevent any rotation.




The present invention also provides for the automated control of the makeup/breakout assembly


40


by a makeup/breakout control system


108


, shown in FIG.


11


. With reference to

FIG. 10

, the makeup/breakout control system


108


automatically coordinates the operation of the makeup/breakout assembly


40


during the process of adding and removing pipe sections


32


to and from the drill string


18


. The makeup/breakout control system


108


comprises a connection sensor assembly


110


and a connection controller


112


. The connection sensor assembly


110


comprises a spindle position sensor


111


and a spindle torque sensor


113


.




The spindle position sensor


111


detects the position of the spindle


26


by monitoring the motor used to thrust the drill string


18


and correlating revolutions of the motor to the distance the spindle travels. The spindle position sensor


111


detects the position of the spindle


26


in the spindle connection area


34


and transmits a


SPINDLE POSITION


signal to the connection controller


112


. The spindle torque sensor


113


detects when the spindle


26


is connected to the drill string


18


by monitoring the pressure in the motor that provides rotation to the drill string. The spindle torque sensor


113


transmits a


SPINDLE CONNECTION


signal to indicate that the spindle


26


is or is not connected to the drill string


18


. In response to the


SPINDLE POSITION


signal and the


SPINDLE CONNECTION


signal, the connection controller


112


will operate the makeup/breakout assembly


40


.




The flow chart of

FIG. 12

depicts an example of logic used by the connection controller


112


during the boring operation when a pipe section


32


is added to the drill string


18


. With reference to

FIGS. 10 and 11

, the connection controller


112


initially waits for the


SPINDLE POSITION


signal at


1202


, indicating that the spindle


26


is at the back end


33


of the spindle connection area


34


so that the pipe section


32


can be added to the drill string


18


. After receiving the


SPINDLE POSITION


signal, the connection controller


112


engages the first wrench


80


at


1204


, effectively securing the drill string


18


and preventing its rotation. Of the plurality of wrench devices, only the first wrench


80


is used during the boring operation. With the first wrench


80


engaged, the spindle


26


can be removed from the drill string


18


by reverse rotation and moved to the back end


33


of the spindle connection area


34


.




After a pipe section


32


is placed in the spindle connection area


34


, rotating and advancing the spindle


26


connects the spindle to the pipe section


32


and the pipe section to the drill string


18


. With the first wrench


80


engaged, the rotation of the spindle


26


and the pipe section


32


in the spindle connection area


34


will make up the connection between the pipe section and the drill string


18


. When the connection is made, the


SPINDLE CONNECTION


signal is received at


1206


, indicating the pipe section


32


has been added to the drill string


18


. The first wrench


80


is then disengaged at


1208


so that the boring operation can proceed at


1210


.




The flow chart of

FIG. 13

illustrates an example of logic used by the connection controller


112


during the backreaming operation when a pipe section


32


is removed from the drill string


18


. With reference to

FIGS. 10 and 11

, the routine waits at


1302


for the


SPINDLE POSITION


signal indicating that the spindle


26


has pulled back so that the pipe section


32


to be removed from the drill string


18


is in the spindle connection area


34


. After receiving the


SPINDLE POSITION


signal, the connection controller


112


engages the second wrench


94


at


1304


to secure the pipe section


32


in the spindle connection area


34


. As the spindle


26


is reverse rotated, the connection between the spindle and the pipe section


32


will be broken and the spindle torque sensor


113


will transmit the


SPINDLE CONNECTION


signal. After receiving the


SPINDLE CONNECTION


signal at


1306


, the connection controller


112


then disengages the second wrench


94


and engages the first wrench


80


and the collar wrench


102


at


1308


.




With the collar wrench


102


engaged, the pipe section


32


will be locked to the spindle


26


and will rotate with the spindle, despite the connection being broken. The rotation of the spindle


26


and the pipe section


32


will then cause the connection to the drill string


18


to be broken and the


SPINDLE CONNECTION


signal will be received at


1310


. The connection controller


112


then disengages the collar wrench


102


at


1312


, and the pipe section


32


in the spindle connection area


34


can be removed by the pipe handling assembly


36


.




After the pipe section


32


is removed from the spindle connection area


34


, the spindle


26


is moved forward and reconnected to the drill string


18


. When the spindle


26


reconnects to the drill string


18


, the


SPINDLE POSITION


signal from the spindle position sensor


111


is received by the connection controller


112


at


1314


. The first wrench


80


is then disengaged at


1316


and the backreaming operation can proceed at


1318


.




An alternative embodiment for the makeup/breakout assembly is shown in detail in FIG.


14


. The embodiment shown therein may be used with or without pipe sections


32


having flats


78


. In this alternative embodiment, the makeup/breakout assembly


40




a


comprises a first wrench


114


and a second wrench


116


. The first wrench


114


is positioned to secure the drill string


18


. The second wrench


116


, adjacent to the first wrench


114


, is positioned to secure the pipe section


32


in the spindle connection area


34


.




The first wrench


114


comprises a hydraulically actuated pair of gripping members


118


. The gripping members


118


are positioned on opposite sides of the drill string


18


and are supported by a horseshoe-shaped holding member


120


. The holding member


120


is attached to the frame


14


to anchor the first wrench


114


. When activated, the gripping members


118


are pressed against the drill string


18


, securing the drill string and preventing it from rotating.




The second wrench


116


comprises a second hydraulically actuated pair of gripping members


122


. The gripping members


122


of the second wrench


116


are positioned on opposite sides of the pipe section


32


in the spindle connection area


34


. When the gripping members


122


are engaged, the gripping members grasp and secure the pipe section


32


in the spindle connection area


34


. A rotatable horseshoe-shaped holding member


124


supports the gripping members


122


. The holding member


124


is rotatable to permit the connection between the pipe section


32


in the spindle connection area


34


and the drill string


18


to be broken. The rotation of the holding member


124


is controlled by a hydraulic cylinder


126


connected at the base of the holding member


124


. As the hydraulic cylinder


126


is operated, the holding member


124


and the pipe section


32


it is holding are rotated slightly. The slight rotation of the pipe section


32


in the spindle connection area


34


, in conjunction with the drill string


18


being secured by the first wrench


114


, permits the connection to be broken.




The instant embodiment of the invention also provides for the automated control of the makeup/breakout assembly


40




a


by the makeup/breakout control system


108


, shown in FIG.


11


and described previously. As with the previously described embodiment, the makeup/breakout control system


108


automatically coordinates the operation of the makeup/breakout assembly


40




a


during the process of adding and removing pipe sections


32


to and from the drill string


18


. During the boring operation when only the first wrench


114


is used, the logic followed by the connection controller


112


of the present embodiment is the same as the logic shown in the flow chart of FIG.


12


and described previously. However, during the backreaming operation when both wrenches


114


and


116


are used, the logic followed by the connection controller


112


is slightly different.




The flow chart in

FIG. 15

illustrates an example of logic used by the connection controller


112


during the backreaming operation when the wrenches of

FIG. 14

are used. The routine waits at


1502


for the


SPINDLE POSITION


signal indicating that the spindle


26


has pulled back so that the pipe section


32


to be removed from the drill string


18


is in the spindle connection area


34


. After receiving the


SPINDLE POSITION


signal, the connection controller


112


engages the first wrench


114


at


1504


to secure the drill string


18


. The connection controller


112


engages the second wrench


116


at


1504


to secure the pipe section


32


in the spindle connection area


34


.




The hydraulic cylinder


126


is activated at


1506


, rotating the holding member


124


, the second wrench


116


, and the pipe section


32


in the spindle connection area


34


. The slight rotation breaks the connection between the pipe section


32


and the drill string


18


. The second wrench


116


is disengaged at


1508


and rotated back to its original position at


1510


. The connection controller


112


engages the second wrench at


1512


, securing the pipe section


32


in the spindle connection area


34


again. The spindle


26


can now be reverse rotated to break the connection between the spindle


26


and the pipe section


32


in the spindle connection area


34


.




When the connection is broken, the spindle torque sensor


113


will transmit the


SPINDLE CONNECTION


signal. After receiving the


SPINDLE CONNECTION


signal at


1514


, the connection controller


112


disengages the second wrench


116


at


1516


, and the pipe section


32


in the spindle connection area


34


can be removed by the pipe handling assembly. With the pipe section


32


removed from the spindle connection area


34


, the spindle


26


is moved forward and reconnected to the drill string. After the spindle


26


reconnects to the drill string


18


, the connection controller


112


receives the


SPINDLE CONNECTION


signal at


1518


and disengages the first wrench


114


at


1520


. The backreaming operation then can proceed at


1522


.




Pipe Lubrication System




Lubricating pipe joints


30


is helpful to prevent the pipe joints from forming too securely. If a lubricant is not used on the pipe joints


30


, galling is possible. Galling can occur when pipe sections


32


of similar material and similar hardness are threaded together without lubricant, causing the pipe joints


30


to fuse together. Therefore, it is desirable to synchronize lubrication of the pipe joints


30


with the making and breaking of drill string


18


connections. One skilled in the art will appreciate that other methods of preventing galling may be used. For example, pipe sections of dissimilar materials or dissimilar hardness could be used. Alternatively, a permanent coating could been used on the pipe joints so that no lubrication is required. Drill pipe with a permanent coating used to prevent galling has appeared in this and related industries, and is disclosed


Innovative Technology for Tubular Connection to Eliminate Thread Compound Grease


, E. Tsuru et al., presented at the 1997 SPE/IADC Drilling Conference, SPE/IADC 37649. If a permanent coating technique or the like is used, no lubrication would be required and the present invention could be implemented without using a lubrication technique. However, as drill pipe requiring lubrication to prevent galling is currently prevalent, the present invention also contemplates a pipe lubrication assembly


38


to lubricate pipe joints


30


as required.




Shown in

FIG. 16

, the pipe lubrication assembly


38


comprises a lubricant reservoir


128


, a pump system


130


, and an applicator


132


. In the preferred embodiment, the pump system


130


comprises a hydraulic pump


134


that transfers lubricant from the reservoir


128


to the applicator


132


. When the pipe joints


30


to be lubricated are in the proper position, a first valve


136


and a second valve


144


supply hydraulic pressure to the hydraulic pump


134


. The hydraulic pump


134


produces a rapid, high pressure lubricant to the applicator


132


. The applicator


132


comprises a nozzle assembly


138


that sprays lubricant onto pipe joints


30


. During the boring operation, lubricant is alternately applied to the connections at both ends of the pipe section


32


that is to be added to the drill string


18


. Consequently, the nozzle assembly


138


preferably comprises a pair of spray nozzles


140


and


142


. A first spray nozzle


140


is positioned to apply lubricant to the spindle pipe joint


28


. A second spray nozzle


142


is positioned to apply lubricant to the exposed pipe joint


30


of the drill string


18


. The lubricant is applied after the spindle


26


disconnects from the drill string


18


, prior to when a new pipe section


32


is connected to the drill string.




During the backreaming operation, lubricant preferably is applied only to the exposed pipe joint


30


of the drill string


18


since the spindle


26


will connect to the drill string in preparation of pulling back. The first valve


136


is activated to enable the second spray nozzle


142


. Consequently, lubricant will be transferred only to the second spray nozzle


142


. One skilled in the art will appreciate that, alternatively, the second valve


144


may enable the first spray nozzle


140


so that the first spray nozzle


140


applies lubricant to the spindle pipe joint


28


.




One skilled in the art will appreciate that other configurations for the spray nozzles


140


and


142


are possible. For example, the present embodiment would be equally effective if the spray nozzles are positioned as shown in the embodiment depicted in

FIGS. 17



a


and


17




b


and described subsequently. The timing of the application of lubricant to the pipe joints


30


will be described hereafter.





FIGS. 17



a


and


17




b


illustrate an alternative embodiment of the pipe lubrication assembly


38




a


. In this embodiment, the pump system


130




a


comprises a pneumatic pump


146


. The pipe lubrication assembly


38




a


applies lubricant to the male threads of the pipe joints


30


as a pipe section


32


is transported to the spindle connection area


34


. A first valve


136




a


supplies pressurized air to the pneumatic pump


146


. The pneumatic pump


146


transfers lubricant to the applicator


132




a


. The applicator


132




a


comprises a nozzle assembly


138




a


that sprays atomized lubricant onto pipe joints


30


. The lubricant is atomized by pressurized air that is supplied to the nozzle assembly


138




a


at the same time that the pneumatic pump


146


is activated.




During the boring operation, lubricant is applied to two pipe joints


30


, at both ends of the pipe section


32


that is to be added to the drill string


18


. Consequently, in this embodiment, the nozzle assembly


138




a


comprises a pair of spaced apart spray nozzles


140




a


and


142




a


. A first spray nozzle


140




a


is positioned to apply lubricant to the pipe section


32


being transferred to the spindle connection area


34


at the end proximate the spindle pipe joint


28


. A second spray nozzle


142




a


is positioned to apply lubricant to the exposed pipe joint


30


of the drill string


18


. The lubricant is applied after the spindle


26


disconnects from the drill string


18


, prior to when a new pipe section


32


is moved into the spindle connection area


34


.




During the backreaming operation, lubricant preferably is applied only to the exposed pipe joint


30


of the drill string


18


after the pipe section


32


is removed from the spindle connection area


34


, since the spindle


26


will connect to the drill string in preparation of pulling back the drill string. A second valve


144




a


is activated to disable the first spray nozzle


140




a


. Consequently, lubricant will be transferred only to the second spray nozzle


142




a


. One skilled in the art will appreciate that other configurations for the spray nozzles


140




a


and


142




a


are possible. For example, the first spray nozzle


140




a


could be configured to apply lubricant to the spindle pipe joint


28


.




The present invention also provides for the automated control of the pipe lubrication assembly


38


or


38




a


, using a pipe lubrication control system. Illustrated in

FIG. 18

, the pipe lubrication control system


148


comprises a lubricate sensor assembly


150


and a lubrication controller


152


. The lubricate sensor assembly


150


determines the relative position of a pipe section


32


being transferred to the spindle connection area


34


and the spindle


26


in the spindle connection area. The lubricate sensor assembly


150


comprises a pipe section position sensor


151


and a spindle position sensor


153


.




During the boring operation, when a pipe section


32


is added to the drill string


18


, the pipe section position sensor


151


transmits a


LUBRICATE PIPE


signal to the lubrication controller


152


, indicating that the pipe section is in a position to be lubricated. The pipe lubrication assembly


38


or


38




a


of the present invention preferably is used in conjunction with the pipe handling assembly


36


. The pipe section position sensor


151


detects the position of the transport assembly


50


by correlating the operation of the drive assembly


52


to the distance traveled by the transport assembly. When the pipe section position sensor


151


detects the pipe section


32


to be added to the drill string


18


is in a position to be lubricated, the pipe section position sensor transmits the


LUBRICATE PIPE


signal. One skilled in the art will appreciate that the pipe section position sensor


151


may be replaced by any device suitable for indicating when the pipe section


32


is positioned so that lubricant can be applied to the pipe joints


30


.




The spindle position sensor


153


is used by the lubrication controller


152


to detect when lubricant is to be dispensed during the backreaming operation. The spindle position sensor


153


detects the position of the spindle


26


by monitoring the motor used to thrust the drill string


18


and correlating revolutions of the motor to the distance the spindle travels. During the backreaming operation, when the spindle position sensor


153


detects the spindle


26


in the spindle connection area


34


proximate the exposed end of the drill string


18


, the spindle position sensor


153


transmits a


SPINDLE POSITION


signal to the lubrication controller


152


. In response to the signals from the lubricate sensor assembly


150


, the lubrication controller


152


activates the pipe lubrication assembly


38


or


38




a


so that the pipe joints


30


are lubricated.




An example of logic followed by the lubrication controller


152


is illustrated in FIG.


19


. The lubrication controller first determines at


1902


if lubricant is being applied during the boring operation or the backreaming operation. During the boring operation, when a pipe section


32


is added to the drill string


18


, the lubrication controller


152


waits at


1904


for the pipe section to be put in position so that the pipe joints


30


can be lubricated. When the


LUBRICATE PIPE


signal is received indicating the pipe section


32


is in position, the first spray nozzle


140


or


140




a


and the second spray nozzle


142


or


142




a


are enabled at


1905


. The pump system


130


or


130




a


is then activated at


1906


and lubricant is delivered to the first spray nozzle


140


or


140




a


and the second spray nozzle


142


or


142




a.






During the backreaming operation, when a pipe section


32


is removed from the drill string


18


, the lubrication controller


152


waits at


1908


for the


SPINDLE POSITION


signal. The


SPINDLE POSITION


signal is transmitted by the spindle position sensor


153


when the spindle


26


is in position for lubricant to be dispensed prior to the spindle reconnecting to the drill string


18


. When the


SPINDLE POSITION


signal is received, the first valve


136


or


136




a


is used to enable the second spray nozzle


142


or


142




a


at


1910


. The lubrication controller


152


then activates the pump system


130


or


130




a


at


1906


, and only the second spray nozzle


142


or


142




a


dispenses lubricant. The


LUBRICATE


routine completes at


1912


.




A third embodiment for the pipe lubrication assembly is shown in

FIGS. 20 and 21

. As shown, the pipe lubrication assembly


38




b


is a passive mechanical apparatus. The pump system


130




b


comprises a rotatable shaft


154


coupled to a piston


156


that pumps lubricant out of the lubricant reservoir


128




b


. The shaft


154


is rotated by a movable arm


158


having a first end that is connected to the shaft and a second end that comes in physical contact with the pipe section


32


to be lubricated. The movable arm


158


is positioned such that, as the pipe section


32


is transported to the spindle connection area


34


in the direction of the arrow A (FIG.


21


), the pipe section will contact the second end of the movable arm, causing the movable arm to pivot. As the movable arm


158


pivots, the shaft


154


rotates in the direction of arrow B (FIG.


21


). The rotation of the shaft


154


causes the piston


156


to compress and pump lubricant out of the lubricant reservoir


128




b


. The lubricant is transferred through a hose assembly


160


to the applicator


132




b


. The applicator


132




b


is positioned so that as the pipe joint


30


to be lubricated passes by the applicator, the pipe joint will brush against the applicator so that lubricant is wiped onto the pipe joint. In the embodiment shown, the applicator


132




b


is part of the movable arm


158


.




During the backreaming operation, when pipe sections


32


are transported from the spindle connection area


34


, the pipe lubrication assembly


38




b


is designed not to dispense lubricant. As the pipe section


32


is transported in the direction opposite arrow A, the pipe section contacts and pivots the movable arm


158


. As the movable arm


158


pivots, the shaft


154


rotates in the direction opposite arrow B. The rotation of the shaft


154


in this direction causes the piston


156


to be withdrawn and not pump lubricant. A torsion spring


162


on the shaft


154


returns the shaft to its original position, regardless of the direction of the shaft rotation.




Automatic Control of Pipe Handling System




The present invention preferably provides for automatic control of the pipe handling system


17


to minimize the need for operator involvement. A machine control system, shown in

FIG. 22

, synchronizes the operations of the pipe handling assembly


36


, the pipe lubrication assembly


38


, and the makeup/breakout assembly


40




a


. The machine control system


170


is activated by the operator and controls the operation of the boring machine


10


when a pipe section


32


is added to, or removed from, the drill string


18


. The machine control system


170


comprises a machine controller


172


that controls the operations of the boring machine


10


.





FIGS. 23 through 31

illustrate flow charts of exemplary embodiments of logic used by the machine controller


172


. One skilled in the art will appreciate that the machine controller


172


can be programmed to control any number of the assemblies to allow the operator as much control as desired. For example, control of the pipe lubrication assembly


38


can be omitted where drill pipe that does not require lubrication is used. Alternatively, the pipe lubrication assembly


38


can be omitted so that the operator can lubricate pipe joints


30


manually as needed, or so that a passive mechanical assembly, such as that shown in

FIGS. 20 and 21

and described earlier, could be used.





FIG. 23

illustrates a main boring operation logic diagram. When a pipe section


32


must be added to the drill string


18


during the boring operation, the operator activates the machine control system


170


by turning a switch or pushing a button at the control panel


24


(see

FIG. 1

) at


2200


. The machine controller


172


waits at


2202


for the


SPINDLE POSITION


signal indicating that the spindle


26


is positioned at the front of the spindle connection area


34


. When the


SPINDLE POSITION


signal is received, the machine controller


172


disables the operator's controls at


2204


. The operation then branches to the


ADD PIPE


routine at


2206


, illustrated in FIG.


24


. When the pipe section


32


has been added to the drill string


18


, control returns at


2208


, and the operator's controls are enabled at


2210


. The operator can then resume the boring operation at


2212


.





FIG. 24

illustrates logic flow for adding a pipe section


32


to the drill string


18


. At


2302


the active gripper device


58




a


, if used, is relaxed. The return arms


49


are lowered at


2304


to place a pipe section


32


in the pipe holding member


56


. The gripper device


58




a


is then closed at


2306


to secure the pipe section in the pipe holding member


56


. The


MAKEUP/BREAKOUT I


routine of

FIG. 25

is then initiated at


2308


to disconnect the spindle


26


from the drill string


18


. When control returns at


2310


, the spindle


26


is positioned at the back end


33


of the spindle connection area


34


. The shuttle arms


55


are extended to the lubrication point at


2312


where the


LUBRICATE


routine of

FIG. 26

is called at


2314


. One skilled in the art will appreciate that an apparatus such as the lubrication sensor assembly


150


, described earlier, can be used to indicate the position of the pipe section


32


to be lubricated.




After the pipe section


32


has been lubricated, the shuttle arms


55


are extended to the spindle connection area


34


at


2318


. The gripper device


58




a


is relaxed at


2320


and the


MAKEUP/BREAKOUT II


routine of

FIG. 27

is called at


2322


to make up the connection between the spindle


26


and the pipe section


32


in the spindle connection area


34


and between the pipe section and the drill string


18


. When control returns at


2324


, the gripper device


58




a


is opened at


2326


. At


2328


the return arms


49


are lifted, and at


2330


the shuttle arms


55


are retracted to the magazine


42


. Control returns to the


MAIN BORING


procedure of

FIG. 23

at


2332


.




The


MAKEUP/BREAKOUT I


routine of

FIG. 25

illustrates how the spindle


26


is disconnected from the drill string


18


during the boring operation before a pipe section


32


is placed in the spindle connection area


34


. The first wrench


114


of the makeup/breakout assembly


40




a


is engaged at


2402


to secure the drill string


18


. The spindle


26


is then rotated in reverse at


2404


to break the spindle connection to the drill string


18


. The routine then waits at


2406


for a signal indicating that the spindle


26


is disconnected from the drill string


18


. An apparatus such as the connection sensor assembly


110


described above could be used to detect when the spindle connection is broken.




When the spindle


26


has been disconnected from the drill string


18


, the rotation of the spindle is stopped at


2408


. The spindle


26


, now free from the pipe section


32


, is then moved to the back end


33


of the spindle connection area


34


at


2410


. Control returns back to the


ADD PIPE


routine of

FIG. 24

at


2412


. The present discussion illustrates automatic control of the makeup/breakout assembly


40




a


of FIG.


14


. Other makeup/breakout assemblies, such as the makeup/breakout assembly


40


shown in FIG.


10


and described earlier, could be automatically controlled by the machine controller


172


.




A


LUBRICATE


routine is shown in

FIG. 26. A

first check is made at


2502


to determine if a pipe section


32


is being added during the boring operation or being removed during the backreaming operation. As discussed earlier, during the backreaming operation only one pipe joint


30


need be lubricated. Thus, during the boring operation the first spray nozzle


140




a


and the second spray nozzle


142




a


are enabled at


2503


. The pump system


130


is then activated at


2504


, and pipe joints


30


are lubricated at both ends of the pipe section


32


being added to the drill string


18


. During the backreaming operation, the second spray nozzle


142




a


is enabled at


2506


. When the pump system


130


is activated at


2504


, only the second spray nozzle


142




a


applies lubricant to the pipe joint


30


on the exposed end of the drill string


18


. Control is returned to the calling procedure at


2508


.





FIG. 27

illustrates logic of a


MAKEUP/BREAKOUT II


routine that connects the spindle


26


to the pipe section


32


in the spindle connection area


34


and the pipe section to the drill string


18


. At


2602


the spindle


26


is rotated and thrust forward to connect to the pipe section


32


and to subsequently connect the pipe section to the drill string


18


. The routine then waits at


2604


for a signal indicating the spindle


26


is connected to the drill string


18


. When the connections are made, the rotation and thrust of the spindle are stopped at


2606


. The first wrench


114


is then disengaged at


2608


so that the drill string


18


can rotate freely and the boring operation can continue at


2610


.





FIG. 28

illustrates a main backreaming operation logic diagram. When a pipe section


32


is to be removed from the drill string


18


during the backreaming operation, the operator activates the machine control system


170


by turning a switch or pushing a button on the control panel


24


(see

FIG. 1

) at


2700


. The machine controller


172


waits for the spindle


26


to be positioned at the back end


33


of the spindle connection area


34


at


2702


. When the spindle


26


is in position, the machine controller


172


disables the operator's controls at


2704


. The operation then branches to the


REMOVE PIPE


routine at


2706


, illustrated in FIG.


29


. When the pipe section


32


has been removed from the drill string


18


, control returns at


2708


and the operator's controls are enabled at


2710


. The operator then can resume the backreaming operation at


2712


.





FIG. 29

illustrates the logic flow for removing a pipe section


32


from the drill string


18


. At


2802


the active gripper device


58




a


is opened to the relaxed position. The return arms


49


are lifted at


2804


to free the shuttle arms


55


from the pipe sections


32


in the magazine


42


. The gripper device


58




a


is then opened at


2806


and the shuttle arms


55


are extended to the spindle connection area


34


at


2808


. The gripper device


58




a


is then closed to the relaxed position at


2810


to support the pipe section


32


in the spindle connection area


34


. The


MAKEUP/BREAKOUT III


routine of

FIG. 30

is initiated at


2812


to disconnect the spindle


26


from the drill string


18


.




When control returns at


2814


, the pipe section


32


in the spindle connection area


34


is free from the spindle


26


and the drill string


18


. The gripper device


58




a


is closed at


2816


to secure the pipe section


32


in the pipe holding member


56


. At


2818


the spindle


26


is rotated in reverse and pulled back from the pipe section


32


in the spindle connection area


34


. One skilled in the art will appreciate that the pipe section


32


is now free from the drill string


18


and the spindle


26


. The return arms


49


are lowered at


2820


and the shuttle arms


55


are then retracted to their position beneath the magazine


42


at


2822


. The


MAKEUP/BREAKOUT IV


routine of

FIG. 31

is called at


2824


to reconnect the spindle


26


to the drill string


18


. When control returns at


2826


, the boring machine


10


is ready to resume backreaming, and control is returned to the


MAIN BACKREAMING


procedure of

FIG. 28

at


2828


.




The


MAKEUP/BREAKOUT III


routine of

FIG. 30

illustrates how the pipe section


32


in the spindle connection area


34


is disconnected from the drill string


18


during the backreaming operation. The first wrench


114


and the second wrench


116


of the makeup/breakout assembly


40




a


are engaged at


2902


to secure the pipe section


32


in the spindle connection area


34


and the drill string


18


. At


2904


the second wrench


116


is rotated to disconnect the pipe section


32


from the drill string


18


. The second wrench


116


is then opened at


2906


and rotated back to its original position at


2908


. At


2910


the spindle


26


and the pipe section


32


are rotated in reverse and pulled back to position the pipe section so that it is free from the drill string


18


, but in position for the second wrench


116


to secure the pipe section. The second wrench


116


is then engaged at


2912


to again secure the pipe section


32


in the spindle connection area


34


.




The spindle


26


is rotated in reverse at


2914


to break but not unscrew the spindle connection to the pipe section


32


. The routine waits at


2916


for the spindle


26


connection to the pipe section


32


to be broken. When the spindle


26


is broken loose from the pipe section


32


, the rotation and pullback of the spindle are stopped at


2918


. The second wrench


116


is then opened at


2920


and the pipe section is pulled back to align it with the magazine


42


at


2922


. One skilled in the art will appreciate that a pipe section


32


in the spindle connection area


34


is now free from the spindle


26


and the drill string


18


. Control then returns back to the


REMOVE PIPE


routine of

FIG. 29

at


2924


.





FIG. 31

illustrates the logic of a


MAKEUP/BREAKOUT IV


routine where the spindle


26


is reconnected to the drill string


18


. At


3002


the spindle


26


is moved to the front end of the spindle connection area


34


. The spindle


26


is rotated and thrust forward to connect to the drill string


18


at


3004


. The routine then waits at


3006


for the spindle


26


to be reconnected to the drill string


18


. When the connection to the drill string


18


is made, the rotation and thrust of the spindle


26


are stopped at


3008


. The first wrench


114


is then opened at


3010


so that the drill string


18


can rotate freely and the backreaming operation can continue at


3012


.




Those skilled in the art will appreciate that variations from the specific embodiments disclosed above are contemplated by the invention. For example, the description of the machine control system


170


incorporates an active gripper device


58




a


as shown in

FIG. 5

, the wrench devices of the makeup/breakout assembly


40




a


illustrated in

FIG. 14

, and the nozzle assembly


138




a


shown in

FIG. 17



a


. However, the use of other assemblies is contemplated. For example, a passive gripper device such as that shown in

FIG. 4

could be used so that the machine control system


170


need not operate the gripper device. Similarly, the makeup/breakout assembly


40


of

FIG. 10

could be substituted and its operation controlled by the machine control system


170


. Where any modification or substitution is contemplated, the logic for the machine controller


172


would have to modified to control the particular assemblies that comprise the pipe handling system.




As described herein, the machine controller


172


of the machine control system


170


is preferably microprocessor based and capable of executing the logic described above to operate the assemblies included in the pipe handling system


17


. However, both microprocessor based and non-microprocessor based systems may be used for controlling the operations of the pipe handling system


17


. For example, the machine control system


170


may comprise a plurality of switches, valves, relays, solenoids, and other electronic or mechanical devices to control and sequence the operations of any of the assemblies of the pipe handling system


17


.




By way of example,

FIG. 32

illustrates an exemplary embodiment of a circuit for controlling the first wrench


80


and the collar wrench


102


of the makeup/breakout assembly


40


of FIG.


10


. The circuit of

FIG. 32

can be used to control the operations of the wrenches during both the boring operation and the backreaming operation, depending on the state of a main control switch. Additionally, the system of

FIG. 32

can be used to open and close the front wrench


80


, engage and disengage the collar wrench


102


, and otherwise control the sequences necessary to operate the makeup/breakout assembly


40


. As shown, the circuit of

FIG. 32

operates in conjunction with the above described systems to control other assemblies and in conjunction with systems for controlling other aspects of the boring machine


10


, such as the thrust and rotation of the spindle


26


.





FIG. 33

illustrates an additional example of a non-microprocessor based machine control system


170


for the pipe handling system


17


. The circuit of

FIG. 33

shows an exemplary embodiment of a circuit for controlling the pipe handling assembly


36


of

FIGS. 3 and 4

. The circuit of

FIG. 33

can be used to control the operations of the pipe handling assembly


36


during both the boring operation and the backreaming operation, depending on the state of a main control switch. Additionally, the system of

FIG. 33

can be used to extend and retract the shuttle arms


55


, raise and lift the return arms


49


, and otherwise control the sequences necessary to operate the pipe handling assembly


36


. As shown, the circuit of

FIG. 33

operates in conjunction with the above described systems to control other assemblies and in conjunction with systems for controlling other aspects of the boring machine


10


, such as the thrust and rotation of the spindle


26


.




Although the present invention has been described with respect to several specific preferred embodiments, various changes, modifications, and substitutions of parts and elements may be suggested to one skilled in the art. Consequently, the invention should not be restricted to the above embodiments and it is intended that the present invention encompass such changes, modifications, and substitutions of parts and elements without departing from the spirit and scope of the invention.



Claims
  • 1. A pipe handling system for use with a horizontal boring machine having a drive system, a drill string comprised of a plurality of pipe sections connectable at threaded pipe joints, a spindle comprising a spindle pipe joint for connecting the drill string to the drive system, and a spindle connection area, the pipe handling system comprising:a makeup/breakout assembly adapted to secure the drill string and at least one pipe section in the spindle connection area as the at least one pipe section is connected to or disconnected from the drill string by executing a plurality of operations; a pipe handling assembly adapted to store and to transport pipe sections to and from the spindle connection area by executing a plurality of operations; a handling assembly control system adapted to automatically operate the pipe handling assembly by initiating and coordinating the plurality of operations executed by the pipe handling assembly; and a makeup/breakout control system adapted to automatically operate the makeup/breakout assembly by initiating and coordinating the plurality of operations executed by the makeup/breakout assembly.
  • 2. The pipe handling system of claim 1 further comprising:a pipe lubrication assembly adapted to apply lubricant to at least one pipe joint by executing a plurality of operations.
  • 3. The pipe handling system of claim 2 wherein the pipe lubrication assembly comprises:a lubricant reservoir; a pump system; and an applicator; wherein the pump system is adapted to transfer lubricant from the lubricant reservoir to the applicator.
  • 4. The pipe handling system of claim 3 wherein the pump system comprises a hydraulic pump.
  • 5. The pipe handling system of claim 3 wherein the applicator comprises a nozzle assembly.
  • 6. The pipe handling system of claim 5 wherein the nozzle assembly comprises:a first spray nozzle positioned to apply lubricant to the spindle pipe joint; and a second spray nozzle positioned to apply lubricant to an exposed pipe joint of the drill string.
  • 7. The pipe handling system of claim 5 wherein the nozzle assembly comprises:a first spray nozzle positioned to apply lubricant to a pipe joint of a pipe section in the spindle connection area at an end of the pipe section proximate the spindle pipe joint; and a second spray nozzle positioned to apply lubricant to an exposed pipe joint of the drill string.
  • 8. The pipe handling system of claim 3 wherein the pump system comprises a pneumatic pump.
  • 9. The pipe handling system of claim 3 wherein the pump system comprises:a rotatable shaft; a piston operatively connectable to the rotatable shaft and adapted to pump lubricant out of the lubricant reservoir; and a movable arm having a first end and a second end, the first end connected to the rotatable shaft and the second end positioned to contact a particular pipe section being transported to the spindle connection area.
  • 10. The pipe handling system of claim 9 wherein the applicator is positioned to contact a particular pipe joint of the particular pipe section, such that as the particular pipe joint comes into contact with the applicator, lubricant is wiped onto the particular pipe joint.
  • 11. The pipe handling system of claim 2 further comprising:a pipe lubrication control system adapted to automatically operate the pipe lubrication assembly by initiating and coordinating the plurality of operations executed by the pipe lubrication assembly.
  • 12. The pipe handling system of claim 11 wherein the pipe lubrication control system comprises:a lubricate sensor assembly adapted to detect a position of the at least one pipe joint to be lubricated and to transmit at least one position signal; and a lubrication controller adapted to receive the at least one position signal and to operate the pipe lubrication assembly.
  • 13. The pipe handling system of claim 12 wherein the lubricate sensor assembly comprises a pipe section position sensor adapted to detect a position of a particular pipe section being transported to the spindle connection area.
  • 14. The pipe handling system of claim 12 wherein the lubrication controller is further adapted to cause the pipe lubrication assembly to apply lubricant to the spindle pipe joint and to an exposed pipe joint of the drill string after the spindle has disconnected from the drill string.
  • 15. The pipe handling system of claim 12 wherein the lubrication controller is further adapted to cause the pipe lubrication assembly to apply lubricant to an exposed pipe joint of the drill string prior to the spindle connecting to the drill string.
  • 16. The pipe handling system of claim 1 wherein the pipe handling assembly comprises at least one gripper device adapted to stabilize the at least one pipe section in the spindle connection area while the spindle pipe joint is being connected or disconnected.
  • 17. The pipe handling system of claim 1 wherein the makeup/breakout assembly comprises:a first wrench adapted to grip and to hold the drill string; and a second wrench adapted to grip and to rotate the at least one pipe section in the spindle connection area.
  • 18. The pipe handling system of claim 17 wherein:the first wrench comprises a plurality of gripping members; and the second wrench comprises a plurality of gripping members.
  • 19. The pipe handling system of claim 1 wherein the makeup/breakout assembly comprises:a first wrench adapted to grip and to hold the drill string; a second wrench adapted to grip and to hold the at least one pipe section in the spindle connection area; and a spindle collar wrench adapted to lock the at least one pipe section in the spindle connection area for rotation with the spindle.
  • 20. The pipe handling system of claim 19 wherein:the first wrench comprises a plurality of opposing surfaces adapted to engage corresponding flats on an exposed end of the drill string; the second wrench comprises a plurality of opposing surfaces adapted to engage corresponding flats on ends of the pipe sections; and the spindle collar wrench is mounted on the spindle and comprises at least one continuous surface adapted to engage corresponding flats on ends of the pipe sections.
  • 21. The pipe handling system of claim 20 wherein the first wrench is adapted to move between a first position and a second position, the opposing surfaces of the first wrench engaging flats on the exposed end of the drill string when the first wrench is in the second position so that the drill string is prevented from rotating.
  • 22. The pipe handling system of claim 20 wherein the second wrench is adapted to move between a first position and a second position, the opposing surfaces of the second wrench engaging flats on an end of the at least one pipe section in the spindle connection area when the second wrench is in the second position so that the at least one pipe section in the spindle connection area is prevented from rotating.
  • 23. The pipe handling system of claim 20 wherein the spindle collar wrench is adapted to move between a disengaged position and an engaged position, the at least one surface of the spindle collar wrench engaging flats on an end of the at least one pipe section in the spindle connection area when the spindle collar wrench is in the engaged position so that the at least one pipe section in the spindle connection area is locked to rotate with the spindle.
  • 24. The pipe handling system of claim 1 wherein the makeup/breakout control system comprises:a connection sensor assembly adapted to transmit at least one signal to indicate when the makeup/breakout assembly is to be operated; and a connection controller adapted to receive the at least one signal and to operate the makeup/breakout assembly.
  • 25. The pipe handling system of claim 24 wherein the connection sensor assembly comprises:a spindle position sensor adapted to detect a position of the spindle and to transmit a spindle position signal; and a spindle torque sensor adapted to detect when the spindle is connected to the drill string and to transmit a spindle connection signal.
  • 26. The pipe handling system of claim 24 wherein the connection controller is further adapted to engage a first wrench and then disengage the first wrench in response to a signal indicating the at least one pipe section in the spindle connection area is connected to the drill string.
  • 27. The pipe handling system of claim 24 wherein the connection controller is further adapted to engage a first wrench and a second wrench, disengage the second wrench in response to a signal indicating the spindle is disconnected from the at least one pipe section in the spindle connection area, engage a spindle collar wrench, disengage the spindle collar wrench in response to a signal indicating the at least one pipe section in the spindle connection area is disconnected from the drill string, and disengage the first wrench in response to a signal indicating the spindle is reconnected to the drill string.
  • 28. The pipe handling system of claim 1 wherein the pipe handling assembly comprises:a magazine adapted to store the pipe sections; and a transport assembly adapted to transport at least one pipe section between the magazine and the spindle connection area.
  • 29. The pipe handling system of claim 28 wherein the transport assembly further comprises:a transport member; and a drive assembly adapted to drive the movement of the transport member; wherein the transport member is adapted to receive and to release at least one of the pipe sections; and wherein the drive assembly is adapted to shuttle the transport member to and from the spindle connection area.
  • 30. The pipe handling system of claim 29 further comprising at least one gripper device supportable on the transport member and adapted to stabilize the at least one pipe section in the spindle connection area.
  • 31. The pipe handling system of claim 1 wherein the handling assembly control system comprises:a handling system sensor assembly adapted to transmit at least one signal to indicate when the pipe handling assembly is to be operated; and a handling assembly controller adapted to receive the at least one signal and to operate the pipe handling assembly.
  • 32. The pipe handling system of claim 31 wherein the sensor assembly comprises:a spindle position sensor adapted to detect a position of the spindle and to transmit a spindle position signal; and a holding member position sensor adapted to detect a position for storing and receiving pipe sections and to transmit a holding member position signal.
  • 33. The pipe handling system of claim 32 wherein the sensor assembly further comprises:a spindle torque sensor adapted to detect when the spindle is connected to the drill string and to transmit a spindle connection signal.
  • 34. The pipe handling system of claim 31 wherein the controller is further adapted to retrieve a particular pipe section from a magazine into a pipe holding member, to extend the pipe holding member from a position beneath the magazine to the spindle connection area, and to retract the pipe holding member to a selected position beneath the magazine in response to a signal indicating the particular pipe section is connected to the drill string.
  • 35. The pipe handling system of claim 31 wherein the controller is further adapted to extend a pipe holding member from a position beneath a magazine to the spindle connection area in order to retrieve a particular pipe section from the spindle connection area, to retract the pipe holding member to a selected position beneath the magazine in response to a signal indicating the particular pipe section is disconnected from the drill string, and to store the particular pipe section in the magazine.
  • 36. A control system for a pipe handling system for use with a horizontal boring machine, the pipe handling system comprising a pipe handling assembly for storing and transporting pipe sections having pipe joints, a pipe lubrication assembly for lubricating at least one pipe joint, and a makeup/breakout assembly, the control system comprising:a handling assembly control system adapted to automatically operate the pipe handling assembly by initiating and coordinating a plurality of operations executed by the pipe handling assembly; a pipe lubrication control system adapted to automatically operate the pipe lubrication assembly by initiating and coordinating the plurality of operations executed by the pipe lubrication assembly; and a makeup/breakout control system adapted to automatically operate the makeup/breakout assembly by initiating and coordinating the plurality of operations executed by the makeup/breakout assembly.
  • 37. The control system of claim 36 wherein the pipe lubrication control system comprises:a lubricate sensor assembly adapted to detect a position of the at least one pipe joint to be lubricated and to transmit at least one position signal; and a lubrication controller adapted to receive the at least one position signal and to operate the pipe lubrication assembly.
  • 38. The control system of claim 36 wherein the makeup/breakout control system comprises:a connection sensor assembly adapted to transmit at least one signal to indicate when the makeup/breakout assembly is to be operated; and a connection controller adapted to receive the at least one signal and to operate the makeup/breakout assembly.
  • 39. The control system of claim 36 wherein the handling assembly control system comprises:a handling system sensor assembly adapted to transmit at least one signal to synchronize the operation of the pipe handling assembly; and a handling assembly controller adapted to receive the at least one signal and to operate the pipe handling assembly.
  • 40. A pipe handling system for use with a horizontal boring machine having a drive system, a drill string comprised of a plurality of pipe sections connectable at pipe joints, a spindle comprising a spindle pipe joint for connecting the drill string to the drive system, and a spindle connection area, the pipe handling system comprising:a pipe handling assembly adapted to store and to transport pipe sections to and from the boring machine by executing a plurality of operations; and a handling assembly control system adapted to automatically operate the pipe handling assembly by initiating and coordinating the plurality of operations executed by the pipe handling assembly.
  • 41. The pipe handling system of claim 40 wherein the pipe handling assembly comprises:a magazine adapted to store a plurality of pipe sections; a transport assembly adapted to transport at least one pipe section between the magazine and the connection area.
  • 42. The pipe handling system of claim 41 wherein the transport assembly further comprises:a transport member; and a drive assembly adapted to drive a movement of the transport member; wherein the transport member is adapted to receive and to release the at least one pipe section; and wherein the drive assembly is adapted to shuttle the transport member between the magazine and the connection area.
  • 43. The pipe handling system of claim 42 further comprising at least one gripper device supportable on the transport member and adapted to stabilize the at least one pipe section in the connection area.
  • 44. The pipe handling system of claim 40 wherein the handling assembly control system comprises:a handling system sensor assembly adapted to detect when the pipe handling assembly is to be operated and transmit at least one signal; and a handling assembly controller adapted to receive the at least one signal and to operate the pipe handling assembly.
  • 45. The pipe handling system of claim 44 wherein the controller is further adapted to retrieve a particular pipe section from a magazine into a pipe holding member, to extend the pipe holding member from a position beneath the magazine to the connection area, and to retract the pipe holding member to the position beneath the magazine in response to the at least one signal.
  • 46. The pipe handling system of claim 44 wherein the controller is further adapted to extend a pipe holding member from a position beneath a magazine to the connection area in order to retrieve a particular pipe section from the connection area, to retract the pipe holding member to the position beneath the magazine in response to the at least one signal indicating the particular pipe section is to be returned to the magazine, and to store the particular pipe section in the magazine.
  • 47. A pipe lubrication system for use with a horizontal boring machine having a pipe handling system comprising a pipe handling assembly for storing and transporting a plurality of pipe sections to and from the horizontal boring machine, the pipe sections having pipe joints at opposing ends of each of the pipe sections, the pipe lubrication system comprising:a pipe lubrication assembly adapted to apply lubricant to at least one pipe joint by executing a plurality of operations; and a pipe lubrication control system adapted to automatically operate the pipe lubrication assembly by initiating and coordinating the plurality of operations executed by the pipe lubrication assembly.
  • 48. The pipe lubrication system of claim 47 wherein the pipe lubrication assembly comprises:a lubricant reservoir; a pump system; and an applicator; wherein the pump system is adapted to transfer lubricant from the lubricant reservoir to the applicator.
  • 49. The pipe lubrication system of claim 48 wherein the pump system comprises a hydraulic pump.
  • 50. The pipe handling system of claim 48 wherein the applicator comprises a nozzle assembly.
  • 51. The pipe lubrication system of claim 50 wherein the nozzle assembly comprises:a first spray nozzle positioned to apply lubricant to a first pipe joint; and a second spray nozzle positioned to apply lubricant to a second pipe joint.
  • 52. The pipe lubrication system of claim 48 wherein the pump system comprises a pneumatic pump.
  • 53. The pipe lubrication system of claim 48 wherein the pump system comprises:a rotatable shaft; a piston operatively connectable to the rotatable shaft and adapted to pump lubricant out of the lubricant reservoir; and a movable arm having a first end and a second end, the first end connected to the rotatable shaft and the second end positioned to contact a particular pipe section being transported by the pipe handling assembly.
  • 54. The pipe lubrication system of claim 53 wherein the applicator is positioned to contact a particular pipe joint of the particular pipe section being transported by the pipe handling assembly, such that as the pipe joint comes into contact with the applicator, lubricant is wiped onto the particular pipe joint.
  • 55. The pipe lubrication system of claim 47 wherein the pipe lubrication control system comprises:a lubricate sensor assembly adapted to detect a position of the at least one pipe joint to be lubricated and to transmit at least one signal indicating the at least one pipe joint is in position to be lubricated; and a lubrication controller adapted to receive the at least one signal and to operate the pipe lubrication assembly.
  • 56. The pipe lubrication system of claim 55 wherein the lubrication controller is further adapted to cause the pipe lubrication assembly to apply lubricant to a first pipe joint of a first pipe section and a second pipe joint of a second pipe section.
  • 57. A makeup/breakout system for use with a horizontal boring machine having a drive system, a drill string comprised of a plurality of pipe sections connectable at threaded pipe joints, a spindle comprising a spindle pipe joint for connecting the drill string to the drive system and a spindle connection area, the makeup/breakout system comprising:a makeup/breakout assembly adapted to secure the drill string and at least one pipe section in the spindle connection area as the at least one pipe section is connected to, or disconnected from, the drill string by executing a plurality of operations; and a makeup/breakout control system adapted to automatically operate the makeup/breakout assembly by initiating and coordinating the plurality of operations executed by the makeup/breakout assembly.
  • 58. The makeup/breakout system of claim 57 wherein the makeup/breakout assembly comprises:a first wrench adapted to grip and to hold the drill string; and a second wrench adapted to grip and to rotate the at least one pipe section in the spindle connection area.
  • 59. The makeup/breakout system of claim 58 wherein:the first wrench comprises a plurality of gripping members; and the second wrench comprises a plurality of gripping members.
  • 60. The makeup/breakout system of claim 57 wherein the makeup/breakout assembly comprises:a first wrench adapted to grip and to hold the drill string; a second wrench adapted to grip and to hold the at least one pipe section in the spindle connection area; and a spindle collar wrench adapted to lock the at least one pipe section in the spindle connection area for rotation with the spindle.
  • 61. The makeup/breakout system of claim 60 wherein:the first wrench comprises a plurality of opposing surfaces adapted to engage corresponding flats on an exposed end of the drill string; the second wrench comprises a plurality of opposing surfaces adapted to engage corresponding flats on ends of the pipe sections; and the spindle collar wrench is mounted on the spindle and comprises at least one continuous surface adapted to engage corresponding flats on the ends of the pipe sections.
  • 62. The makeup/breakout system of claim 61 wherein the first wrench is adapted to move between a first position and a second position, the opposing surfaces of the first wrench engaging flats on the exposed end of the drill string when the first wrench is in the second position so that the drill string is prevented from rotating.
  • 63. The makeup/breakout system of claim 61 wherein the second wrench is adapted to move between a first position and a second position, the opposing surfaces of the second wrench engaging flats on an end of the at least one pipe section in the connection area when the second wrench is in the second position so that the at least one pipe section in the connection area is prevented from rotating.
  • 64. The makeup/breakout system of claim 61 wherein the spindle collar wrench is adapted to move between a disengaged position and an engaged position, the at least one surface of the spindle collar wrench engaging flats of an end of the at least one pipe section in the connection area when the spindle collar wrench is in the engaged position so that the at least one pipe section in the connection area is locked to rotate with the spindle.
  • 65. The makeup/breakout system of claim 57 wherein the makeup/breakout control system comprises:a connection sensor assembly adapted to detect when the makeup/breakout assembly is to be operated and to transmit at least one signal; and a connection controller adapted to receive the at least one signal and to operate the makeup/breakout assembly.
  • 66. The makeup/breakout system of claim 65 wherein the connection controller is further adapted to engage a first wrench and to then disengage the first wrench in response to the a signal indicating the pipe section in the spindle connection area is connected to the drill string.
  • 67. The makeup/breakout system of claim 65 wherein the connection controller is further adapted to engage a first wrench and a second wrench, to disengage the second wrench in response to a signal indicating the spindle is disconnected from a particular pipe section in the connection area, to engage a spindle collar wrench, to disengage the spindle collar wrench in response to a signal indicating the particular pipe section is disconnected from the drill string, and to disengage the first wrench.
  • 68. A horizontal boring machine comprising:a frame; a drill string comprised of a plurality of pipe sections connectable at threaded pipe joints; a drive system attachable to the frame adapted to rotate and to axially advance the drill string substantially horizontally through the earth, the drive system having a spindle comprising a spindle pipe joint for connecting the drive system to the drill string; and an automated pipe handling system adapted to add and to retrieve pipe sections to and from the drill string by executing a plurality of operations, the automated pipe handling system comprising: a pipe handling assembly adapted to transport the pipe sections to and from a spindle connection area; a makeup/breakout assembly adapted to secure the drill string and at least one pipe section as the at least one pipe section is connected to or disconnected from the drill string; and a control system adapted to operate the pipe handling system by initiating and coordinating the plurality of operations.
  • 69. The horizontal boring machine of claim 68 further comprising:a pipe lubrication assembly adapted to apply lubricant to at least one pipe joint.
  • 70. The horizontal boring machine of claim 69 wherein the pipe lubrication assembly comprises:a lubricant reservoir; a pump system; and an applicator; wherein the pump system is adapted to transfer lubricant from the lubricant reservoir to the applicator.
  • 71. The horizontal boring machine of claim 70 wherein the pump system comprises a hydraulic pump.
  • 72. The horizontal boring machine of claim 70 wherein the applicator comprises a nozzle assembly.
  • 73. The horizontal boring machine of claim 72 wherein the nozzle assembly comprises:a first spray nozzle positioned to apply lubricant to the spindle pipe joint; and a second spray nozzle positioned to apply lubricant to an exposed pipe joint of the drill string.
  • 74. The horizontal boring machine of claim 72 wherein the nozzle assembly comprises:a first spray nozzle positioned to apply lubricant to a pipe joint of a pipe section in the spindle connection area at an end of the pipe section proximate the spindle pipe joint; and a second spray nozzle positioned to apply lubricant to an exposed pipe joint of the drill string.
  • 75. The horizontal boring machine of claim 70 wherein the pump system comprises a pneumatic pump.
  • 76. The horizontal boring machine of claim 70 wherein the pump system comprises:a rotatable shaft; a piston operatively connectable to the rotatable shaft and adapted to pump lubricant out of the lubricant reservoir; and a movable arm having a first end and a second end, the first end connected to the rotatable shaft and the second end positioned to contact a particular pipe section being transported to the spindle connection area.
  • 77. The horizontal boring machine of claim 76 wherein the applicator is positioned to contact a particular pipe joint of the particular pipe section, such that as the particular pipe joint comes into contact with the applicator, lubricant is wiped onto the particular pipe joint.
  • 78. The horizontal boring machine of claim 68 wherein the pipe handling assembly comprises at least one gripper device adapted to stabilize the at least one pipe section in the spindle connection area while the spindle pipe joint is being connected or disconnected.
  • 79. The horizontal boring machine of claim 68 wherein the makeup/breakout assembly comprises:a first wrench adapted to grip and to hold the drill string; and a second wrench adapted to grip and to rotate the at least one pipe section in the spindle connection area.
  • 80. The horizontal boring machine of claim 79 wherein:the first wrench comprises a plurality of gripping members; and the second wrench comprises a plurality of gripping members.
  • 81. The horizontal boring machine of claim 68 wherein the makeup/breakout assembly comprises:a first wrench adapted to grip and to hold the drill string; a second wrench adapted to grip and to hold the at least one pipe section in the spindle connection area; and a spindle collar wrench adapted to lock the at least one pipe section in the spindle connection area for rotation with the spindle.
  • 82. The horizontal boring machine of claim 81 wherein:the first wrench comprises a plurality of opposing surfaces adapted to engage corresponding flats on an exposed end of the drill string; the second wrench comprises a plurality of opposing surfaces adapted to engage corresponding flats on ends of the pipe sections; and the spindle collar wrench is mounted on the spindle and comprises at least one continuous surface adapted to engage corresponding flats on ends of the pipe sections.
  • 83. The horizontal boring machine of claim 82 wherein the first wrench is adapted to move between a first position and a second position, the opposing surfaces of the first wrench engaging flats on an exposed end of the drill string when the first wrench is in the second position so that the drill string is prevented from rotating.
  • 84. The horizontal boring machine of claim 82 wherein the second wrench is adapted to move between a first position and a second position, the opposing surfaces of the second wrench engaging flats on an end of the at least one pipe section in the spindle connection area when the second wrench is in the second position so that the at least one pipe section in the spindle connection area is prevented from rotating.
  • 85. The horizontal boring machine of claim 82 wherein the spindle collar wrench is adapted to move between a disengaged position and an engaged position, the at least one surface of the spindle collar wrench engaging flats of an end of the at least one pipe section in the spindle connection area when the spindle collar wrench is in the engaged position so that the at least one pipe section in the spindle connection area is locked to rotate with the spindle.
  • 86. The horizontal boring machine of claim 68 wherein the pipe handling assembly comprises:a magazine adapted to store the pipe sections; a transport assembly adapted to transport at least one pipe section between the magazine and the spindle connection area.
  • 87. The horizontal boring machine of claim 86 wherein the transport assembly further comprises:a transport member; and a drive assembly adapted to drive a movement of the transport member; wherein the transport member is adapted to receive and to release at least one of the pipe sections; and wherein the drive assembly is adapted to shuttle the transport member to and from the spindle connection area.
  • 88. The horizontal boring machine of claim 87 further comprising at least one gripper device supportable on the transport member and adapted to stabilize the at least one pipe section in the in the spindle connection area.
  • 89. The horizontal boring machine of claim 69 further comprising:a pipe lubrication control system adapted to automatically operate the pipe lubrication assembly by initiating and coordinating a plurality of operations executed by the pipe lubrication assembly.
  • 90. The horizontal boring machine of claim 89 wherein the pipe lubrication control system comprises:a lubricate sensor assembly adapted to detect a position of the at least one pipe joint to be lubricated and to transmit at least one position signal; and a lubrication controller adapted to receive the at least one position signal and to operate the pipe lubrication assembly.
  • 91. The horizontal boring machine of claim 90 wherein the lubricate sensor assembly comprises a pipe section position sensor adapted to detect a position of a particular pipe section being transported to the spindle connection area.
  • 92. The horizontal boring machine of claim 90 wherein the lubrication controller is further adapted to cause the pipe lubrication assembly to apply lubricant to the spindle pipe joint and to an exposed pipe joint of the drill string after the spindle has disconnected from the drill string.
  • 93. The horizontal boring machine of claim 90 wherein the lubrication controller is further adapted to cause the pipe lubrication assembly to apply lubricant to an exposed pipe joint of the drill string prior to the spindle connecting to the drill string.
  • 94. The horizontal boring machine of claim 68 wherein the control system comprises:a handling assembly control system adapted to automatically operate the pipe handling assembly; and a makeup/breakout control system adapted to automatically operate the makeup/breakout assembly.
  • 95. The horizontal boring machine of claim 94 wherein the pipe handling control system comprises:a handling system sensor assembly adapted to transmit at least one signal to indicate when the pipe handling assembly is to be operated; and a handling assembly controller adapted to receive the at least one signal and to operate the pipe handling assembly.
  • 96. The horizontal boring machine of claim 95 wherein the sensor assembly comprises:a spindle position sensor adapted to detect a position of the spindle and to transmit a spindle position signal; and a holding member position sensor adapted to detect a position of a particular pipe section being transported to the spindle connection area and to transmit a holding member position signal.
  • 97. The horizontal boring machine of claim 96 wherein the sensor assembly further comprises:a spindle torque sensor adapted to detect when the spindle is connected to the drill string and to transmit a spindle connection signal.
  • 98. The horizontal boring machine of claim 95 wherein the handling assembly controller is further adapted to retrieve a pipe section from a magazine into a pipe holding member, extend the transport member from a position beneath the magazine to the spindle connection area; and retract the transport member to the position beneath the magazine in response to a signal indicating the pipe section is connected to the drill string.
  • 99. The horizontal boring machine of claim 95 wherein the handling assembly controller is further adapted to extend a pipe holding member from a position beneath a magazine to the spindle connection area in order to retrieve a particular pipe section from the spindle connection area, to retract the pipe holding member to the position beneath the magazine in response to a signal indicating the particular pipe section is disconnected from the drill string, and to store the particular pipe section in the magazine.
  • 100. The horizontal boring machine of claim 94 wherein the makeup/breakout control system comprises:a connection sensor assembly adapted to transmit at least one signal to indicate when the makeup/breakout assembly is to be operated; and a connection controller adapted to receive the at least one signal and to operate the makeup/breakout assembly.
  • 101. The horizontal boring machine of claim 100 wherein the connection sensor assembly comprises:a spindle position sensor adapted to detect the position of the spindle in the spindle connection area and to transmit a spindle position signal; and a spindle torque sensor adapted to detect when the spindle is connected to the drill string and to transmit a spindle connection signal.
  • 102. The horizontal boring machine of claim 100 wherein the connection controller is further adapted to engage a first wrench and to then disengage the first wrench in response to a signal indicating a particular pipe section in the spindle connection area is connected to the drill string.
  • 103. The horizontal boring machine of claim 100 wherein the connection controller is further adapted to engage a first wrench and a second wrench, to disengage the second wrench in response to a signal indicating the spindle is disconnected from a particular pipe section in the spindle connection area, to engage a spindle collar wrench, to then disengage the spindle collar wrench in response to a signal indicating the particular pipe section in the spindle connection area is disconnected from the drill string, and to disengage the first wrench.
  • 104. A method for drilling a horizontal borehole comprising:advancing a boring tool through the earth using a drill string comprised of a plurality of pipe sections connected at threaded pipe joints; and repeatedly adding individual pipe sections to the drill string by performing a plurality of operations to transfer pipe sections to the drill string, wherein the plurality of operations are automatically initiated and coordinated.
  • 105. The method of claim 104 further comprising performing a plurality of operations to apply lubricant to at least one pipe joint prior to adding each individual pipe section, wherein the plurality of operations are automatically initiated and coordinated.
  • 106. The method of claim 105 wherein the plurality of operations for applying lubricant to the pipe joint comprises:sensing a position of a particular pipe section being added to the drill string; and applying lubricant to a particular pipe joint on the drill string or to another pipe joint on the particular pipe section being added to the drill string.
  • 107. The method of claim 104 further comprising performing a plurality of operations to secure the drill string while a particular pipe section being added to the drill string is rotated to engage a particular threaded connection, wherein the plurality of operations are automatically initiated and coordinated.
  • 108. The method of claim 107 wherein the plurality of operations for securing the drill string comprises:sensing a position of the drill string; engaging a first wrench with the drill string; sensing when the particular pipe section being added to the drill string has been connected to the drill string; and disengaging the first wrench.
  • 109. The method of claim 104 wherein the plurality of operations for delivery of individual pipe sections to the drill string comprises:retrieving a particular pipe section from a storage position in response to a signal indicating that the particular pipe section is to be added to the drill string; and transporting the particular pipe section to a connection area for connection to the drill string.
  • 110. A method for backreaming a horizontal borehole comprising:pulling a drill string composed of a plurality of pipe sections connected at threaded pipe joints back through a previously bored horizontal borehole; and repeatedly removing the pipe sections from the drill string as the drill string is shortened by performing a plurality of operations to transfer pipe sections away from the drill string, wherein the plurality of operations are automatically initiated and coordinated.
  • 111. The method of claim 110 wherein the plurality of operations for transporting pipe sections away from the drill string comprises:retrieving a particular pipe section from the drill string in response to a signal indicating that the particular pipe section is to be removed from the drill string; and transporting the particular pipe section to a storage position.
  • 112. The method of claim 110 further comprising performing a plurality of operations to apply lubricant to a particular pipe joint on the drill string after a particular pipe section is removed from the drill string, wherein the plurality of operations are automatically initiated and coordinated.
  • 113. The method of claim 112 wherein the plurality of operations for applying lubricant to the particular pipe joint comprises:sensing when a particular pipe section has been removed from the drill string; and applying lubricant to the drill string before the drill string is further pulled back through the borehole.
  • 114. The method of claim 110 further comprising performing a plurality of operations to secure the drill string while a particular pipe section being removed from the drill string is rotated to disconnect the threaded connection, wherein the plurality of operations are automatically initiated and coordinated.
  • 115. The method of claim 114 wherein the plurality of operations for securing the drill string comprises:sensing the position of the particular pipe section to be removed from the drill string; engaging a first wrench with the drill string; sensing when the particular pipe section to be removed from the drill string has been disconnected from the drill string; and disengaging the first wrench.
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