Drilling Head With Bayonet Coupling

This invention relates to well drilling apparatus and more particularly to an improved rotating drilling head. The drilling apparatus generally comprises a rotatable drill stem used to rotate a drill bit within the well. The drill stem may include a string of drill pipes connected with a non-circular cross-section pipe, commonly referred to as a kelly, slidably extending downwardly through the rotary table. The kelly, being a part of the drill stem, transmits the drive from the rotary table to the drilling head via the kelly bushings. In the usual forward circulation drilling operation, a drilling fluid such as a liquid or compressed air or gas may be forced through the interior of the hollow drill stem and drill bit at the bottom of the well bore. Cuttings and debris at the bottom of the well are entrained in the drilling fluid and carried upwardly in the annulus between the outside of the drill stem and the inside surface of the well bore or casing. In a reverse circulation drilling operation, the drilling fluid is pumped down the annulus between the well bore or casing and forced upward through the drill bit and interior of the hollow drill stem.

The rotating drilling head is attached to the top of a well stack which may have a conventional blowout preventer at its upper end.

The drilling head includes a stationary outer housing or tubular spool which is secured to the top of the stack, a drive ring and bearing assembly, and a drive assembly which is matable with the drive ring and bearing assembly. The drive assembly includes a split kelly bushing. A rubber stripper is attached for rotation with the drive ring in slidable sealing engagement with the kelly drive.

In operation, the split kelly bushing is slidably connected to the kelly drive. As the kelly drive is lowered through the drilling head the kelly bushing is received within the drive assembly. Rotation of the kelly causes the kelly bushing to rotate which rotates the drive assembly, which in turn rotates the drive ring and attached rubber stripper. Thus, in operation, there is no relative rotational movement between the rubber stripper and the kelly drive.

Various arrangements have been provided for removing worn drilling head components from the spool. In certain arrangements, an expandable/contractible split clamp is employed to removably secure such drilling head components to the spool. Such clamps incorporate a plurality of pivoting segments which together may be moved radially outward or inward by a remote controlled hydraulic motor driven screw. Such remote control eliminates the need for a workman to go under the rig floor and manually operate the clamp. Problems have been experienced with such split clamps. For example, mud and debris tend to accumulate about the clamp segments which obstructs proper radial movement. Also, it is necessary to connect/disconnect a lubrication line directly to the spool at a location relatively remote from the bearing assembly.

An object of the invention is to facilitate the assembly, installation, operation and maintenance of a drilling head in which components subject to wear may be readily removed for replacement and reinstalled.

Another object of the invention is to releasably secure removable components to the drilling head spool with a reliable clamp which operates properly in the presence of mud and debris which tends to obstruct the remote controlled operation of multi-segmented clamps.

Still another object of the present invention is to facilitate lubrication of the rotating components, seals and the bearing assembly of the drilling head.

The above objects and many other objects, features and advantages of the present invention will become apparent to those skilled in the art when the detailed description of the preferred embodiment is read in conjunction with the drawings.

The present invention provides a rotating drilling head with an upper body assembly which houses a kelly bushing, drive and bearing assembly, along with a stripper. The upper body assembly is secured to a tubular spool by a rotatable clamp via a bayonet-type coupler arrangement. The clamp is selectively rotated between clamped and unclamped positions by a remote controlled hydraulic motor. Quick connect/disconnect lubrication couplings provided on the outside of the upper body assembly and the clamp are releasably mated upon rotation of the clamp to the clamped position to provide lubrication from a single source to the rotating components, seals and the bearing assembly contained in the upper body assembly via passageways formed in the outer body.

The kelly bushing is split into two complementary parts configured and interfitted to be fastened together by bolts accessible from above the top of the kelly bushing.

FIG. 1 is an elevation, partly in section, showing the drilling head of the present invention;

FIG. 2 is a side elevation view of the drilling head of the present invention partially broken away to show the hydraulic motor and pinion gear;

FIG. 3 is a rear elevation partially fragmented to show the hydraulic lock manifold and hydraulic hoses;

FIG. 4 is an elevation of the upper body assembly removed from the drilling head of FIG. 3;

FIG. 5 is an enlarged fragmentary view of a portion of the lower body of FIG. 1 illustrating lubrication passageways;

FIG. 6 is a fragmentary section taken along the plane 6--6 of FIG. 2 with the upper body assembly in a clamped position and partially fragmented to show the mating of the lubrication couplings in the clamped position;

FIG. 7 is a section taken along plane 7--7 of FIG. 2 showing the upper body assembly in the unclamped position; and

FIG. 8 is a schematic diagram showing the hydraulic circuit of the hydraulic motor of the drilling head.

Referring now to the drawing, the drilling head of the present invention is generally indicated by the reference numeral 10 and includes an upper body assembly 12, a spool 14 and a clamp 16. The upper body assembly 12 is releasably secured to the spool 14 in a bayonet fashion upon rotation of the clamp 16 in response to the remote control actuation of a hydraulic motor 20. In operation, the drilling head 10 is disposed below a rotary table (not shown) of conventional construction on the upper side of a derrick floor (not shown). The rotary table includes a rotatable, hollow, noncircular shaped kelly which extends through a bushing in the rotary table, downward into the drilling head 10 through a kelly bushing 58 past an elastomeric stripper 126 and out the bottom opening of the drilling head. A power transmitting mechanism rotates the kelly extending through the rotary table. A drilling string attached to the kelly is rotated therewith. The drilling string may include a series of vertically stacked hollow drill stems or pipes connected one to the other with the kelly connected to the uppermost drill stem.

An inlet flange 18 is provided at the base of the spool 14 for securing the drilling head 10 to a mating flange at the upper end of a well casing or the top flange of a blow out preventer. An outlet nipple 22 is formed on one side of the casing of the drilling head 10 to enable the discharge of fluid from the side opening of the drilling head 10. The outlet nipple 22 is provided with external threads 24 for securing a suitable fluid conduit to the housing of the drilling head 10 in order to conduct fluid therefrom.

The upper body assembly 12 includes an outer body 24 which supports a top plate seal holder assembly 26, a lower end seal holder assembly 28, and a drive bushing assembly 30. Lifting brackets 32, each having an eyelet 34, is secured to the outer housing 38 of the drive bushing assembly 30 via bolts 36 to facilitate lowering the entire upper body assembly 12 through the clamp 16 onto the spool 14 and also for lifting the entire upper body assembly 12 from the drilling head 10 when the clamp 16 is rotated to the unclamped position as described later.

The outer housing 38 is provided with a plurality of circumferentially spaced holes 40 through the outer housing base 42. A circular drive bushing adapter plate 44 is provided with a plurality of circumferentially spaced holes 46 vertically aligned with the holes 40. The outer housing 38 is secured to the drive bushing adapter plate 44 by a plurality of circumferentially spaced bolts 48 extending downwardly through the aligned holes 40 and 46. An elastomeric intermediate shock absorber 50 is sandwiched between the outer drive bushing housing 38 and an inner drive bushing member 52. The outer surface 54 of the inner drive bushing member 52 is mated with and bonded to the shock absorber 50. The shock absorber 50 functions to isolate shock and vibration between the inner drive bushing member 52 and the outer drive bushing housing 38 (FIG. 6). The shock absorber 50 is generally corrugated in cross-sectional shape. The configuration of the inner surface 56 of the outer housing 38 is complementary in configuration to the generally corrugated cross-sectional shape of the shock absorber 50. This design results in rotational drive being transmitted to the drive bushing housing 38 from the kelly bushing 58 even if the shock absorber or cushion 50 should deteriorate to a degree or if the bond between the shock absorber 50 and the outer surface 54 of the inner drive bushing member 52 fails.

As can be seen in FIGS. 1 and 6, the kelly bushing 58 is split in two complementary kelly bushing members 60 and 62 interfitted together. A lower side portion of member 60 is interfitted underneath an upper side portion of member 62 on one side of the kelly bushing 58. On the opposite side of the kelly bushing 58 an upper portion of member 60 is disposed directly above and interfitted with a complementary lower portion of member 62. Members 60 and 62 thus may be bolted together from the top via bolts 64 through the counterbored bolt holes 66 which are aligned with the underlying threaded holes 68.

The upper body assembly 12 includes a bearing assembly 70 sandwiched between the outer body 24 of the drilling head 10 and a rotatable drive ring 72 (FIG. 1). The bearing assembly 70 is sealed at its upper end by the top plate seal holder assembly 26 and at its lower end by the lower end seal holder assembly 28. An upper wear ring 74 is provided within an annular recess 76 at the top of the drive ring 72. An O-ring 78 is disposed in an annular groove 80 approximate the lower end of the upper wear ring 74. Lip seals 82 are provided in annular grooves formed on the inner surface of the top plate seal holder assembly 26. A passageway 84 communicates lubrication to the upper wear ring 74 between the lip seals 82. A check valve 86 closes the outer end of the passageway 84 and insures that lubrication flows only in the direction of the annular space between the upper wear ring 74 and the top plate seal holder assembly 26.

The drive ring 72 is provided with an external annular shoulder 88 which supports a lower inner bearing race 90. A spacer ring 92 is provided around the drive ring 72 between the bearing race 90 and an upper inner bearing race 94 which is held in place by a lock ring 96 threadably secured to the drive ring 72. A spacer ring 98 separates the outer races 100 and 102. A spacer ring 104 separates the upper outer race 102 from the top plate seal holder assembly 26. The bearing assembly 70 further includes a plurality of tapered roller bearings 106 positioned between lower inner race 90 and outer race 100. A plurality of tapered roller bearings 108 are positioned between upper inner race 94 and outer race 102. The bearing assembly 70 thus limits both horizontal and vertical movement of the drive ring 72 which is rotatable with respect to the outer body 24 of the drilling head 10.

A lower wear ring 110 is positioned within an annular recess 112 provided about the outer surface at the lower end of the drive ring 72. The lower end seal holder assembly 28 is provided with three inner lip seals 114 which are in rotatable contact with the lower wear ring 110. The lip seals 114 are disposed in annular grooves 116 formed in the inner surface of the lower end seal holder 28. A pair of O-rings 118 provide a seal at the upper and lower outer surface of the seal holder 28 and the inner surface of the body 24. The lower end seal holder assembly is secured to the body 24 via a plurality of circumferentially spaced bolts 120.

A stripper adapter plate 122 is secured to the underside of the drive ring 72 via a plurality of circumferentially spaced bolts 124. Secured to and extending downwardly from the stripper adapter plate is a stripper or wiper member generally designated 126 formed of elastomeric material and adapted to engage a kelly or drill stem in fluid sealing contact. A stiffener member 128 is bonded within the upper portion of the wiper 126. The stiffener member 128 is generally cylindrical and includes an outwardly extending horizontal flange 130 through which the stripper may be secured to the underside of the stripper adapter plate 122 via a plurality of circumferentially spaced bolts 132.

Referring now to FIGS. 1 through 7, the bayonet coupling arrangement of the present drilling head invention will now be described. A plurality of circumferentially spaced apart segments 134 are integral with and extend radially outwardly from the lower portion of the outer body 24. A plurality of segment receiving openings 136 are formed on the inner surface of the rotatable clamp 16. The segment receiving openings 136 are complementary in size and configuration to corresponding segments 134. Corresponding pairs of segments 134 and openings 136 differ from other corresponding pairs in size and configuration to ensure that the upper body assembly 12 is received in the rotatable clamp 16 only in proper orientation. This facilitates connection of lubrication coupling 138, which is mounted on the outer body 24 with the lubrication coupling 140 provided on the rotatable clamp 16 upon rotating the clamp 16 into the clamped position (FIG. 6). It is important that the couplings 138 and 140 properly mate with each other upon rotation of the clamp 16 to the clamped position so that lubricating oil can be provided to the lower wear ring 110, the bearing assembly 70, and the upper wear ring 74, as will be described later. The clamp lubrication coupling 140 is a male coupling member adjustably mounted on a boss 142 via a threaded adjusting rod 144 (FIGS. 6 and 7). A cushion ring may be provided around the adjusting rod 144 in order to compensate for minor misalignment and absorb any shock when the male coupling member 140 is mated with the female coupling member 138 upon rotation of the clamp 16 into the fully clamped position.

A pair of markers 146, 148 are provided at the top of the outlet nipple 22. An orientation projection 150 is provided at a suitable location on the outer surface of the clamp 16 for visual confirmation by an observer on the derrick floor that the clamp 16 has been fully rotated such that the orientation projection 150 is aligned between the markers 146 and 148. If desired, a visual marker 152 (FIG. 4) may similarly be provided on the outer surface of the outer body 24 to provide a visual indication that the marker 152 is aligned between the markers 146 and 148, thereby indicating proper orientation of the upper body assembly 12 as it is lowered into the rotatable clamp 16 with the clamp 16 in the unclamped position. Clamp eyelets 154 are secured to the clamp 16 to facilitate both the lowering and raising of the clamp 16 and spool 14.

A plurality of circumferentially spaced apart segments 137 are integral with and extend radially inwardly from the upper inner surface of the clamp 16 (FIGS. 1 and 7). Upon full rotation of the clamp 16 to the clamped position, the radially inwardly extending segments 137 are disposed directly above the radially outwardly extending segments 134 on the outer body 24 of the upper body assembly 12 (FIG. 1). The lower surface of each clamp segment 137 is spaced above the top surface of the spool 14 to provide clearance for the upper body segments 134 only. During rotation of the clamp 16 from the unclamped position toward the clamped position, the lower surface of each clamp segment 137 scrapes along the top surface of its corresponding segment 134 thereby scraping away any accumulated mud or debris. This enhances the reliability of the clamping operation and reduces maintenance requirements.

The clamp 16 includes an upper clamp section 156 and a lower clamp section 158. The upper and lower clamp sections 156, 158 are secured together by a plurality of circumferentially spaced clamp bolt means 160. The lower clamp section 158 is rotatable within an annular groove 162 formed at the upper outer surface of the spool 14 (FIG. 1). The lower clamp section 158 includes a ring gear 164 formed on an arcuate section thereof. The ring gear 164 is driven by a pinion gear 166 which is keyed onto the shaft 168 of the hydraulic motor 20. An override extension 170 is secured to the upper end of the pinion gear 166 and is provided with a plurality of wrench flats for manually rotating the pinion gear 166 in the event of hydraulic motor failure. A guard cover 172 is provided over the pinion gear 166 and the ring gear 164. The hydraulic motor 20 is mounted on a motor mounting bracket 174 which is bolted to a boss 176 on the outer surface of the spool 14 via bolts 178.

Referring now to FIG. 5, lubrication is provided via a lubrication plug 404 in the outer body 24. A lube oil transfer passage 406 provides lubrication oil from the lubrication plug 404 to an annular cavity 408 about the lower portion of the bearing assembly 70. Lubrication oil is also provided to an annular cavity 410 between the uppermost and intermediate seals 114 from the passageway 412. A check valve 414 is provided at the outermost part of passage 412 to insure lubrication oil flow in the proper direction. Similarly, lubrication oil is provided to annular cavity 416 via passageway 418 and check valve 420. The check valves 414 and 420 operate to balance pressures about the lip seals 114. For additional structural integrity, an O-ring 422 is provided in a downwardly facing recess of the lowermost lip seal 114.

Referring now to FIG. 8, a hydraulic control circuit is shown for operating hydraulic motor 20. Hydraulic fluid is supplied to motor 20 via hydraulic lines 302 and 304 coupled at their opposite ends to a hydraulic lock manifold 306. Hydraulic fluid is supplied to the hydraulic lock manifold 306 via lines 308 and 310. 80 pounds psi air is input to the circuit via line 312 to the input of an air filter 314. Filtered air is provided from the output of filter 314 to the input of an air regulator 316 having an output in turn coupled to one of two inputs of a directional air control valve 318 via lubricator 320. The output of the directional air control valve 318 is provided to an air/oil booster 322 via lines 324 and 326. The hydraulic output of the air/oil booster 322 is fed to a hydraulic directional control valve 328 via lines 330 and 332. The output of the hydraulic directional control valve 328 is supplied via lines 308 and 310 to the hydraulic lock manifold 306 which includes dual pilot to open check valves. With this air/hydraulic circuit the hydraulic motor 20 can be powered to rotate the clamp 16 in either a clamp engaging or a clamp releasing direction.