Apparatus for use in drilling Background of the Invention This invention relates to apparatus for use in drilling. It has previously been the practice in well drilling to impart motive force to the drill string or other tubular members being worked by means of a rotary table drive or by an electric motor top drive. Rotary drive tables are inefficient and costly. Electric top drives have had numerous problems; for example, to move and support drill strings weighing up to 500 tons, the direct current traction motors used must be very large, consequently they require a large and effective motor cooling system. Above all there are considerable potential safety hazards associated with the use of an electric top drive. Because of these potential hazards obtaining compliance with accepted safety codes and insurance certification for the use of electric top drives has been a tedious, expensive, and time-consuming process. There are also numerous structural and functional disadvantages associated with the use of electric top drives. Thus, one prior art electric top drive utilizes an expensive thrust bearing to support the drill string rather than using the shaft of the motor itself. Another prior art electric top drive has an electric motor which is offset from the shaft supporting the drill string. The central drive shaft of the electric motor is not directly connectable to the drill string nor is it directly connectable via an intermediate sub or other member. Therefore, a means for transferring rotative force from the electric motor to the drill string must be employed; e.g., a system of reduction gears between the motor and a tubular member which is connectable to the string. This results in an imbalance in the distribution of the reactive torσue

applied to the string.

One type of top drive previously used in drilling includes a pipe handling mechanism suspended below and connected to the top drive gear box (see U.S. Patent No. 4 449 596). This top drive also uses a pipe wrenching device supported in suspension from the gear box and both its pipe handling mechanism and the pipe wrenching device are permanently disposed about the tubular drive shaft projecting from the bottom of the top drive. In actual operation, the pipe wrenching device is actuated upwardly to engage splines located about the circumference of the tubular drive shaft. When drill rotation is stopped, the pipe wrenching device can be used to break a threaded connection between the powered drive unit and the drill string, and the pipe handling mechanism can then support the drill string remaining in the drill hole. This top drilling drive utilizes an electric motor to impart the necessary rotary motion to the drill string. Utilities, cables, and other connections to the top drive to the electric motor must of necessity be flexible since they must travel up and down with the top drive.

The previously described top drive assembly has a number of operational disadvantages. Power to the drive motor is provided through rubber covered flexible conductors. These conductors are largely unprotected from accidental short circuits which might occur if the conductor cable was pinched between metal objects. Since all drilling rigs are located in hazardous areas this could be life threatening. The electric motor must also be cooled and the cooling air is transported through flexible ducts which can fail if they are of a flimsy nature. The motors must be completely sealed to prevent the emission of sparks from the carbon brushes, but it has proved difficult to do so reliably. The pipe

wrenching device has been another source of problems because its working mechanism needs hydraulic fluid but the top drive shaft on which it is supported has to rotate which involves the provision of a high pressure rotary fluid connection on the top drive shaft which is very costly and unreliable because it combines high working pressures and large diameter. Remotely operated shut-off valves incorporated into the top drive assembly have failed. These valves all use a ball with a hole through the centre through which abrasive drilling fluids pass. The present valves do not provide a satisfactory method of ensuring the ball is fully open or closed. When the ball is not oriented properly, fluid passage erodes the ball very quickly. A drill pipe pick-up tool that depends from the top drive assembly requires a central shaft of the top drive to be fitted about its vertical axis to enable a new section of pipe to be picked up. With this method it is impossible to pick up a length of drill pipe without exerting extreme pressure on the side of the pipe. This results in undue wear on the drill pipe and also on the "mouse hole". (A "mouse hole" is a hole near the rig in which pipe is placed for pick up).

Other operational disadvantages of the top drive of U.S. Patents 4 449 596 and 3 766 991 include the fixed rollers on the "dolly". This fixture secures all the other top drive components to the derrick guide rail system. Since there is no flexibility in the dolly roller system to compensate for irregularities, many roller failures have been experienced in the field. It has been difficult to obtain certification for use of electric top drives in hazardous areas. Because of the electrical and cooling system requirements, several safety devices in the form of electrical switches must be provided. Individual components require

certifications and the entire installation must be approved by a recognized authority. This is very time consuming and expensive.

Prior art hydraulic top drives such as that described in U.S. Patent 3 994 350 have a hydraulic motor which is offset from the centreline resulting in an imbalance of loading of the central shaft. An endless chain is driven by the hydraulic motor and the chain, in turn, drives a drive unit which can be threadedly connected to pipe.

The present invention is directed . to a hydraulic top drive apparatus and to a tubular handling device that, at least in preferred embodiments, mitigates the problems associated with the prior art devices. Mounted in a derrick beneath a conventional crown block, travelling block, bail, and swivel, preferred embodiments of the present invention include a hydraulically powered top drive pipe rotating device having a single hollow drive shaft with threads at each end for mating on one end with the drill string or tubular to be worked and on the other with a drilling swivel. This shaft can be positioned coaxially with the vertical axis of both the wellbore and the drill string so that a balanced concentric force is imparted to the string. The top drive rotating device is attached to a wheeled support frame. The frame moves on guide rails which are mounted to the derrick. The mounting of the top drive apparatus permits it to be pivoted levelly in' a horizontal plane away from the vertical axis of the wellbore and of the drill string or other tubulars. Motive force is applied directly to the drill string or other tubular being worked. Also, the top drive is fully reversible so that motive force can be applied in either direction. A makeup/breakout wrenching device is retractibly connected to the wheeled support frame. It

is movable independently of the top drive and is positioned beneath the top drive. A pipe lifting and positioning device is mounted beneath the top drive on the wheeled support frame for picking up pipe and for positioning it so that the pipe threads can mate precisely with the threads of the top drive shaft. The drillpipe lifting and positioning device may be extended as desired - this allows picking up pipe from a "mousehole". Also the device's ability to rotate makes the radial location of mousehold unimportant. The device is adjustable in the three motions available; degree of rotation, length of extension and height of elevation. Thus, the operator can pre-set the degree of the various motions and then by simply turning a valve handle, effect the desired action which is automatically accomplished with the hydraulic sequencing valves. Presently available systems require more manual effort. Also, other systems after picking up the pipe, lower the pipe (sometimes as much as 862 kg (1900 lbs)) into the mating thread. This undue force rapidly wears and sometimes damages the threads. At least preferred embodiments of apparatus according to the present invention raise the drill pipe toward an already rotating mating thread. Since the upward thrust can be accurately be controlled by adjusting a valve, thread life can be greatly extended. Thus preferred embodiments of the present invention provide a semi-automated drilling system, which is more precise and which reduces human error. A preferred top drive drilling system embodying the present invention includes a hydraulically powered drive head which eliminates the inherent safety problems present with electrical equipment in an oil well drilling derrick. A top drive drilling system according to the ^■

present invention can include a drill pipe handling mechanism -which is mounted independently from the top drive central shaft both eliminating the need for a tilting mechanism, and increasing the versatility of the tool since the pipe handling mechanism can be programmable to reach any required pick up location required within the confines of the drill floor. The pipe lifter/positioner can elevate drill pipe to connect it to the drill stem. Since the pipe wrenching tool can be mounted independently of the top drive rotating shaft, the need for a rotating high pressure hydraulic coupling is eliminated. Prior art Patent No. 4 449 596 suspends a hydraulically powered wrenching tool directly below the drive motor gear box. This wrenching tool is subsequently engaged to the centrally located rotating shaft through the use of mating splines. Since fluid conductors must be employed to drive the tool, some form of rotary seal must be used (which often must seal effectively when fluid pressures approach 138 bar (2000 p.s.i.)). The device of U.S. Patent No. 4 529 045 as fitted to the top drive of U.S. Patent No. 4 449 596 accomplishes the transfer of fluid. This wrenching means can also be provided with a- mechanism which will retract the tool completely away from the well centreline. The same mechanism can extend the assembly to the proper position from which to grip and wrench the drill pipe joint.

A particular feature of a preferred top drive power head according to this invention is the use of input pinion .drive gears. The input gears contain a female spline which is fitted with a splined sleeve. Whereas the ^' outside spline is machined to fit the gear, the female spline is machined to fit the various sizes of hydraulic motors. This allows a change in horsepower simply by changing to a larger or smaller motor and an

appropriate splined sleeve.

Another feature of various embodiments of the present invention is that both the pipe lifter/positioner and the pipe wrenching means may be easily swung or retracted away from the centreline of the well. When withdrawing a drill string from the hole, the spiral shape of the customary drill pipe stabilizers imparts a rotary motion to the drill stem. When this happens, the elevator links and the drill pipe elevators must of necessity rotate also. The present invention allows this to happen naturally since the pipe wrench and the pipe positioner are mounted independently of the drive mechanism.

The present invention discloses an improved operator for the remote shut off valve. The design is such that the open/close limits of the valve ball operating mechanism can be positively set before installation in the drill string. The cylinders which operate the valve shift yoke have an adjustable stroke which can be effected by external adjustments. The rack and pinion operator provided is also less susceptible to wear and will hold its adjustment indefinitely. The preferred embodiment also discloses a quick disconnect which may be used to connect the top drive unit to the drilling swivel normally found directly below the drill rig travelling block. It is very inconvenient and also dangerous to operate rig pipe tongs at an elevation of 2.4 - 3.6 m (8 to 12 feet) above the drill floor. The preferred embodiment allows the making or breaking of this threaded connection without using a tong. Counterbalance cylinders may be located between the drilling swivel and the travelling block. In the event of malfunction, this component is easily removed for service. The design also allows a shorter overall assembly length which facilitates usage in a shorter

derrick. Many prior art units require so much derrick space that derrick rework to increase the height becomes necessary.

Preferred apparatus according to the present invention allows drilling down to the drill floor. Prior art units are able to drill to within only 0.9 - 1.2 m (3 - 4) feet of the floor. Even to do that, prior art units require a mechanism to elevate the pipe handling equipment in • a vertical direction. This is both cumbersome and inefficient.

The preferred embodiment discloses pipe wrenching means in which one set of the pipe wrench jaws are operable when selected to be in such a mode. This allows the pipe wrench to act as a drill stem locking brake. The operator will select the proper action by manipulating a valve. This feature is valuable since it is desirable to lock the drill stem when directional drilling and checking the down hole orientation with instruments. The drill pipe positioner arm control system of this invention is versatile. The pickup arm may be controlled with conventional hydraulic components, but it is also adaptable and may be fitted with solid state electronic controls. Although these controls are electrical, they are intrinsically safe and usually are not able to ignite explosive gases. The electronic control is programmable which greatly improves the efficiency of the pipe manipulator arm. If desired a driller can be provided with a control "box" which has among other features various potentiometers. These adjust a command signal to actuator cylinders which contain linear variable displacement transducers which send a feedback signal to the control "box". When the input signal and the feedback are equal, the hydraulic supply to the cylinders cut off. At the outset of drilling the operator can set

the rotation limit potentiometer, the extend distance potentiometer and the lift limit potentiometer. Once this is . done, by flipping a switch all three actions occur in correct sequence and accurately. The pipe positioner mounting frame according to this invention can have a plurality of guide roller/bracket assemblies. Each roller complex can include two spring loaded rollers which allow shock absorber action in two dimensions. This design has two distinct advantages: the cushioned support reduces vibration and stress on the top drive and it also allows the guide rail installation inaccuracies to be compensated for. Since the spring tension is adjustable, each installation may be custom fitted. A preferred top drive drilling system according to the present invention can provide a rotary drive powered drilling head utilizing fluid power. Fluid energy is inherently smoother and produces fewer shock loads than mechanical forms of energy. This feature is extremely important since drill pipe twisted off, several thousand feet below the surface presents many problems. The torque applied by fluid motors is smoother and causes less over-tightening and swelling of drill pipe threaded connections. When drill pipe breaks, an electric motor will inherently overspeed when the load is suddenly removed. This can be very dangerous. Prior art units have in many cases been required to add an overspeed switch and brake to prevent runaway. Hydraulic motors will not overspeed because pump displacement controls their speed and a sudden break will simply lower the pressure. The incompressible fluid can dynamically inhibit runaway.

The pipe lifter/positioner arm can include a pivoted pickup bowl which is fitted ^~ with energy absorbing springs to reduce shock damage to drill pipe.

The pickup bowl is also hard surfaced at point in contact with drill pipe.

Thus preferred embodiments of the invention can provide an efficient and safe hydraulic top drive ^" for use in well operations which imparts a concentric and balanced motive force to the tubular to be worked and in which a full rated torque output can be achieved within safe operating limits. It can further provide means for pivoting a top drive pipe handling apparatus levelly in a horizontal place away from the drill string or other tubulars being worked without having to tilt the top drive from the vertical. It can still further provide a top drive apparatus in which its shaft itself supports the drill string so that no thrust bearing support is required.

Preferred embodiments of the invention can further provide a top drive apparatus in combination with a pipe lifting and positioning device in which: both of them are mounted on a wheeled support which in turn is mounted on rails connected to the derrick for moving the top drive apparatus and pipe positioning device up and down within the derrick; in which they are both movable to some extent with respect to the frame itself; and in which they are both mounted and movable independently of the top drive.

A further feature of the invention in a preferred aspect is the provision of such a top drive in which the pipe positioning device can be pivoted levelly in a horizontal plane away from the drill string or other tubular being worked without it having to be fitted from the vertical.

Another preferred feature of the present invention is the provision of a device for precisely lifting and positioning drill pipe. Yet another feature of the present invention

in a preferred aspect is the provision of a hydraulic top drive apparatus which limits the lifting distance of the drill bit off the bottom of the hole when making connections of pieces of the drill string. Since drilling down flush with the drill floor is possible with devices according to the present invention, to elevate the pipe far enough to set the slips (wedge-shaped support devices) requires that the drill bit be moved only about three feet from bottom. Prior art top drives requires elevation of six to eight feet and the old Rotary/Kelly method requires elevations of thirty-four to thirty-six feet.

Still another preferred feature of the invention is the provision of such a top drive with which drill pipe connections may be broken at a wide range of elevations in the derrick and which provides smooth rotary torque at these elevations.

Another preferred feature of the present invention is the provision of such a top drive which can be utilized for normal drilling, reaming and casing operations, can be used to drill with single or multiple sections of pipe, can ream in 27.5 (ninety-foot) increments, can be used to connect tubular members without using spinning chains or tongs and has a rise and fall counter-balance system.

A further feature of this invention is to ensure that the drive motor will not "run away" in the event of breakage of drill pipe. When drilling with a normal 27.5 m (ninety foot) stand of pipe, if the pipe breaks near the bottom of the stand, the sudden increase of electric motor torque would create an uncontrolled "whipping" of the pipe which is very dangerous.

For a better understanding αf the invention and to show how the same may be carried into effect reference will now be made, by way of example, to the accompanying drawings in which Figures 1 - 11 show a drilling rig as described in our UK Patent Specification No. 2 167 105 and Figures 12 - 34 show a second form of drilling rig according to the invention. More particularly:-

Figure 1 is a schematic elevation of a drilling rig provided with apparatus according to the present invention;

Figure 2 is a top plan view of the pipe positioning apparatus taken on line II-II of Figure 1;

Figure 3 is a sectional view of a bail link; Figure 4 is a. sectional view of a splined quick disconnect;

Figure 5 is a section on line V-V of Figure 4;

Figure 6 is a top view, particularly in section, of a breakout/makeup wrenching device assembly; Figure 7 is a side view of the assembly of

Figure 6;

Figure 8 shows, on an enlarged scale, a detail of the assembly shown in Figure 7;

Figure 9 is a bottom view, partially in section, of the lower section of the assembly of Figure

7;

Figure 10 is a section on line X-X of Figure

9; Figure 11 is a section on line XI-XI of Figure 9;

Figure 12 is a schematic side elevation showing a second form of the well drilling rig having a top drive assembly, a pipe wrenching mechanism, a remotely operable shut-off valve, a pipe elevator mechanism, a quick disconnect mechanism and a pipe

positioner mounting frame constructed and arranged in accordance with various aspects of the invention;

Figure 13 is a half rear view '"of a pipe positioner gimbal; Figure 14 is a diagrammatic view of the derrick as it appears from under the top drive;

Figures 15 and 16 are sectional views of a counterbalance link assembly and a quick disconnect assembly; Figure 17 is a view in half section of a top drive power head;

Figure 18 is a detail of the upper surface of a pinion stub-shaft forming part of the drive power head; Figure 19 is a view in side section of part of the drill string below the top drive power head showing a remote shutoff valve in the drill string and part of an operating mechanism for the valve which fits below the top drive power head; Figure 20 is a partial view of the drill string at 90 degrees to Figure 19 showing provision for rack and pinion operation of the valve and positive setting of the stroke of the valve by means of an adjustable stop member; Figures 21 and 22 are plan and diagrammatic side views of a pipe wrenching device;

Figure 23 is a further partial plan view of the pipe wrenching device with a horizontal centreline separating a half view with the device open to accept drillpipe and a half view with the device closed to clamp drillpipe;

Figure 24 is a sectional view of the pipe wrenching device;

Figure 25 is a further plan view of the pipe wrenching device showing its attachment to a support

frame;

Figure 26 is a side view of a wrenching device showing how a breakout cylinder is mounted thereon;

Figure 27 is a view in cross-section of a pipe positioning manipulator arm with a gimbal frame to which the arm is attached also shown in section and the pickup bowl shown in side view; ^*

Figure 28 is a lower view of the manipulator arm showing a second stage retract cylinder; Figures 29 and 30 are respectively a section and a plan view of the pickup bowl;

Figures 31, 32 and 33 are side, top and end views respectively of a roller bracket assembly; and

Figure 34 is a sectional view of an elevator link adaptor.

THE SYSTEM OF OUR UK PATENT SPECIFICATION NO. 2 167 105

Referring now to Figure 1, a top drive 10 is suspended from a commercially available swivel 11 fitted with optional bail links 12. The bail links 12 are, in turn, attached to a travelling block 13 which is attached by cables to a crown block 14 in the derrick

15. The top drive 10 is attached to a support frame 16 which is slidably mounted on guide rails 17 which are mounted on the derrick 15. The attachment of the top drive 10 to the shaft of swivel 11 may be made through a one piece threaded hollow shaft or by using a splined quick disconnect 18. The hydraulic fluid which operates the top drive 10 is conducted through pipes 19 and hoses

20 from a power unit 21 located at a convenient point. The top drive 10 has a hollow shaft 30 with a threaded top end 30a for connection to the splined quick disconnect 18.

The top drive 10 is attached to the support frame 16 in such a manner that it may be rotated in a horizontal plane about pivots 22 on the wheeled support

frame 16 for maintenance or removal from service. A drill pipe positioning arm 23 is also pivoted from the support frame 16 in such a manner that it may be rotated in a horizontal plane to a drill pipe pick-up point using cylinders 24 (Figure 2). The drill pipe positioning arm 23 may be moved to a point which positions the drill pipe 66 directly over the centreline of the well being drilled. Additional cylinder(s) 25 (Figure 1) then elevate the drill pipe 66 to allow a screwed connection to be made to either: the threaded bottom end 30b of hollow shaft 30, the threaded bottom end of an elevator link adaptor 27 (when it is used), or to the threaded and of the saver sub 67 when it is used. Since the motive force of the top drive 10 is centred about the hollow shaft 30, the reactive forces are substantially balanced and a substantially concentric balanced force is imparted to the drill string.

A wrenching device having an upper section 26 and a lower section 31, is also pivotably connected to the support frame 16 in such a manner that it may be rotated aside in a horizontal plane to allow access for maintenance or removal.

Referring again to Figure 1, the positioning arm 23 is provided with a bowl 33 which has a tapered seat to match the drill pipe tool joint. A lateral opening 35a is provided across which extends a latch 35. The latch 35 can be displaced to allow the entry of a drill pipe. The latch 35 is spring loaded to the closed position. Drill pipe may be loaded by pushing into the opening 35a. A cylinder 36 is used to move the latch 35 to the open position. Cylinder 25, when actuated, moves the drill pipe 66 into contact with the mating thread on the saver sub 67. The latch 35 may also be actuated manually. Referring now to Figure 3, each bail link 12

has a piston 34. hich is biased upward in a cylinder barrel 34a as a result of fluid under pressure entering the interior of the barrel 34a from an accumulator 38. The internal force acts like a compression spring. When the piston 34 is actuated downward by a load the potential energy is stored within the hydraulic accumulator 38. When the load is next reduced, such as when a section of the drill string is being unscrewed, the distance between the attaching holes 43a and 43b will decrease, the drill string proper will remain stationary in the hole and the swivel 11 will move upward as the threaded members of the drill string are separated. When the sections are unscrewed the upper section is raised clear of the drill string proper by the action of the piston 34 within the barrel 34ja. When the load is entirely removed, the distance between the attaching holes 43a _^ and 43b will be at minimum. Packing seals 37 are provided circumjacent the piston 34.

Referring to Figures 4 and 5, the splined quick disconnect 18 comprises (a) a tubular member 40 provided with a male spline and an extension bearing a sealing element 42, and (b) a section 41 provided with a female spline which co-operates with the male spline. A threaded collar 39 mates with the threads on the section 41. An inside shoulder 45 on collar 39 abuts a projection 44 on member 40 and thereby locks the assembly as a splined and sealed unit. Torque is transmitted through the splines.

Referring to Figure 6, the upper section 26 of the wrenching device has a box section 56 securely attached to support members 50. A die block 52 is attached to inner die carrier 53 by pins 58. Die blocks 51 and 52 are able to move inward or outward on guides 57. Cylinder 60, when pressurized in chamber 65, moves die block 51 into contact with tubular workpiece 62. As

die block.51 engages workpiece 62 a reaction force moves inner die carrier 53 in a direction away from workpiece 62 until die block 52 which is attached to inner die carrier 53 is forced to engage workpiece ^* 62. In operation, pressure in chamber 65 creates a gripping force which firmly engages serrated dies 64 against the workpiece 62. In the reverse action, cylinder 60 is pressurized in chamber 63 causing die block 51 to move away from workpiece 62. After partial travel, die block 51 will contact stops 54 which will cause the body of cylinder 60 and the inner die carrier 53 to move inward toward the workpiece 62. This action forces the die block 52 away from workpiece 62.

Referring now to Figure 9, which is a bottom view of the lower section 31 of the wrenching device, a box section 56' is securely attached to a circular guide plate 55. Die block 52' is attached to an inner die carrier 53' with pins 58'. Die blocks 51' and 52' are able to move inwardly and outwardly, being aligned by guides 57'. Cylinder 60', when pressurized in chamber 65', moves die block 51' to contact tubular workpiece 62. As die block 51' engages workpiece 62, a reaction force moves inner die carrier 53 ' in a direction away from the workpiece 62 until die block 52 ' engages workpiece 62. In operation, pressure in chamber 65' creates a gripping force which firmly engages serrated dies 64' against workpiece 62.

In the reverse action, the cylinder 60' is pressurized in chamber 61' causing die block 51' to move away from workpiece 62. After partial travel, die block 51' will contact stops 54' which causes the body of cylinder 60' to move toward the workpiece 62. Since inner die carrier 53' is attached to cylinder 60', inner die carrier 53' will move toward workpiece 62 and force die block 52' away from the workpiece 62, the force

being transferred through pins 58' which attach die block 52' to inner die carrier 53' . Torque arms 68 are securely attached to box section 56' .

Referring to Figures 8 and 10, the circular guide plate 55 features a guide lip 69 which will be used in attaching the assembly of Figure 9 to the upper section of the wrenching device shown in Figure 6.

Referring now to Figure 11, a typical section through either the top wrenching section or the lower wrenching section is shown illustrating the method of attaching an inner die carrier (53, 53' ) to a die block (52, 52') using a pin (58, 58').

Referring now to Figure 7, cylinders 70 are affixed to respective torque arms 68 of the wrenching device through a clevis at the rod end. The barrel end is connected to the upper section through a hinged joint 71 and the reaction is restrained by the upper section. When the cylinders 70 are energizes, the lower section will rotate the centreline of the low die blocks about axis y. The guide lip 69 rotates in annular groove 72 (Figure 8). When bolts 73 are removed the wrenching device is free to pivot in a horizontal plane on support frame 16.

With this embodiment well drilling fluids enter the drill string through a conventional flexible hose connected to the swivel 11 shown in Figure 1. The swivel 11 has a hollow shaft through which fluids pass into the hollow shaft 30 of the top drive 10 and on through the hollow sections of the remaining subs or devices into the interior of the drill string.

The following chart compares certain features (but not all) of the embodiment described with reference to the drawings with the embodiments disclosed in U.S. Patent 4 449 596 and with the Bowen ES-7 Electric Drilling Swivel:

In the following comparison Prior Art is identified by the letters PA and Preferred Embodiment by the letters PE.

Bowen ES-7 Electric Drill Swivel

PA: Electrical power is conducted from the generating room to the unit through rubber covered electrical cables. Danger of damaging and sparking is ever present. An accident at a time when well head gasses are present could be disastrous.

PE: Operated by hydraulic fluid, There is no danger of sparking. The hydraulic power unit is located in a safe area. PA: Complete drilling system weights approximately 18,000 kg.

PE: Complete system weights 9,000 kg or less. PA: In the event of mechanical failure requires complete "rig down"; the replacement of the electric top drive is complex and time consuming.

PE: Unit is designed to accommodate rapid replacement of the hydraulic top drive. Because of this feature several hours of down time are saved.

PA: All installations are equipped with a conventional (rotary table) drive system on "standby" because of high down time is replacement of electric top drive required.

PE: Reliability of this system and ease of replacement would allow users to eliminate the rotary table drive systems, spare hydraulic motors and components ae the only "back-up" equipment. This saves hundreds of thousand dollars rig cost.

PA: Hazardous area certificates are required for the numerous safety devices used to monitor systems designed to render this unit safe for use in a hazardous

location. This is time consuming and expensive.

PE: Electrical devices are located below the drill floor in a pressured safe room which would, in any event normally already exist. The multitude of monitoring devices used on the electric drive are not required.

PA: During drilling, excessive bit weight or hole friction and stops the drill bit and stalls the electric motor. Common practice is to reduce bit weight. Since full electrical potential remains applied, the drill suddenly accelerates from zero to up to 250 R.P.M. in a matter of seconds. This causes over-tightening of tool joint threads and ruins the drill pipe. Also the drill string may whip and damage the wall of the hole. Mechanical reaction is transmitted to the derrick through the support mechanisms and this vibration damages the structure and is very noisy.

PE: Hydraulic power, because of its inherent nature, is much smoother. The mechanism of the moving fluid are such that acceleration after stall will be smoother and more uniform. Less damage to drill hole and equipment are realized.

PA: Air purging the inside of the electric drilling motor is required at initial start-up and at every time a safety device actuates. This may require 10 to 30 minutes.

PE: No purging is required because there is no air cooling system.

PA: On units so equipped there is a danger of water leaking into the electric motor following any damage or corrosive failure of the water to air heat exchanger used to cool the motor air. These systems are required wherever you ^" find stringent safety measures such as North Sea Platforms. This can cause the motor to fail.

PE: No such system is required.

PA: Making drill pipe connection: the drill pipe is picked up by the_elevator bowl and the lower end stabbed in the previous_ pipe. Human skill is then required to ease the drive shaft down into the thread to screw it up. Thread damage can occur.

PE: The pipe handling device on this unit has a hydraulic lift to engage the thread. Proper adjustment will ensure minimal pressure on the threads. This is much quicker than when the driller has to execute skill and judgement making up each joint of pipe.

PA: When picking up a length of drill pipe whose end is protruding about lm above the drill floor, the pipe handler must be tilted outward. Since the bowl of the pickup tool is swivelled, the angle is incorrect for the pipe. Also the latches on the pickup tool must be manually closed which takes time.

PE: substantially perfect alignment and orientation of the pipe handling mechanism is achieved via mechanical stops and cylinders to create the necessary movement. The latch is spring loaded to automatically lock when the pipe is loaded. A cylinder will actuate the latch to the open position. This is by remote control which is much safer. This system is also much faster than the manual method.

PA: Cost much more.

PE: This system cost much less. This does not take into account the equipment which an operator does not have to buy, such as extra swivel and/or rotary table drive which would make the savings several hundred thousand dollars.

PA: Installing this unit on land rigs or retrofitting to offshore rigs is very complicated because of size and different system. PE: Retrofit to any existing drilling rig can

be accomplished much easier because of size and weight as well as simplicity of design.

PA: The closed circuit air cooling system collects carbon dust which emanates from the bushes. This can lead to internal shorting. PE: No brushes are used.

PA: Repeated stalling of the main electric motor especially for more than a few moments, under high current will damage the armature and subsequent rotation will lead to failure.

PE: No such stalling problem.

Also, the embodiment described compares favourably to that disclosed in the prior art U.S. Patent 4, 449,596 in the following respects: PA: Requires two circulating swivels because one is integral with power sub and one must be used when unit is rigged down.

PE: Only one swivel is required. Current list price for a 500 ton swivel (Continental Emsco): $43,290.00.

PA: Requires explosion proof cooling air system. Present design uses blower mounted ^" on support dolly or drill floor and air is conducted through 20 cm diameter flexible rubber duct. This lightweight duct is often windblown and damaged from hanging on the rig structure. Hot air is exhausted to atmosphere creating a hazardous condition. Documentation for the alternating current fan motor and approval for the D.C. drive motor is time consuming and expensive. PE: Hydraulic oil is cooled by rig supplied water being circulated through an oil cooler. This equipment is located in an existing safe location.

PA: The overall height, width and depth is much greater; requires approximately 13.8 m of vertical derrick height.

PE: This unit requires less than 10.8 m.

PA: The unit does not have a "rise and fell" mechanism to minimize load on drill stem threads when unscrewing. PE: Counterbalance mechanism is provided.

PA: Unit must be swung back in order to install well casing.

PE: All normal drilling and casing installation is done with standard unit. THE PREFERRED DRILLING RIG OF THE INVENTION

The preferred drilling rig of the invention which has certain similarities in construction and manner of operation to that described in Figures 1 - 11 will now be described in detail. In Figure 12 there is shown a second form of the top device assembly generally indicated by the reference numeral 126. A travelling block 125 is connected through counterbalancing links 130 to a swivel

129. Below the swivel 129 a shaft thereof is attached to a quick disconnect 131 which attaches an hydraulically powered drive unit 132 to the swivel 129. The drive unit

132 is powered by four hydraulic motors 168 disposed symmetrically about the central shaft 156 and having outputs along axes parallel to but offset laterally from the axis of the central shaft 156. A shut-off valve 133 and an elevator link adaptor are fitted below the hydraulically powered drive unit 132 which is connected to a support frame 135 by mounting brackets 136. A retractible wrenching device 137 and a drill pipe manipulator are also attached to the support frame 135.

The wrenching device 137 is movable under the control of a retract cylinder 143. Figure 13 is a partial rear view of the support frame 135 and shows the drill pipe manipulator 138 pivotably mounted on a manipulator gimbal frame 139. Lifting cylinders 140 connected to the

gimbal frame 139 elevate the frame 139 and the drill pipe manipulator 138 carried thereby to enable the threads of a new section of drill pipe to engage automatically during a drilling operation. In Figure 14 the central shaft 156 appears below a housing 157 of the hydraulically powered drive unit 132. Covers 120 for the undersides of four pinion gears 162 (Figure 17) appear on the underside of the housing 157 symmetrically about the central shaft 156 and it may be seen that the mounting brackets 136 extend from opposite sides of the housing 157 to respective sides of the support frame 135. A manipulator arm rotate cylinder 142 that oscillates on the gimbal frame 139 between the position shown in solid lines and the position shown in phantom has a rod connected to the drill pipe manipulator 138 at a position behind a pivot 119 of the manipulator 138 to the gimbal frame 139. Retraction of the rod into the cylinder 142 rotates the drill pipe manipulator 138 from a first position normal to the support frame 135 where its tip is aligned with the drill string to a second position skew to the support frame 135 where its tip approaches a drill pipe racking board or other desired location in the derrick. As described in more detail below, the support frame 135 is supported on derrick guide rails of H- or C-section by rollers 240, 241 which permit the support frame 135 to be moved up and down the rails 127 by the travelling block 125.

The structure of the links 130 that connect the travelling block 125 and the swivel 129 is shown in Figure 15. Each link 130 has a piston 144 which is biased upwards in a cylinder barrel 145 as a result of fluid under pressure entering the interior of the barrel 145 f om an hydraulic accumulator 146. The internal force acts like a compression spring. When the piston

144 is activated downward by a load, the potential energy is stores within the hydraulic accumulator 146. Nitrogen or other gaseous working fluid within the accumulator 146 is separated from oil or other hydraulic fluid flowing from and to the interior of the barrel 145 by means of a movable membrane 146a. When the load is next reduced, such as when a section of the drill string is being unscrewed, the distance between the attachment holes 147a, 147b will decrease, the drill string proper will remain stationary in the hole and the swivel 129 will move upward as the threaded members of the drill string are separated. When the sections are unscrewed the upper section is raised clear of the drill string proper by the action of the piston 144 within the barrel 145. When the load is entirely removed, the distance between the attaching holes 147a, 147b will be at a minimum. The links 130 may either be used with a lifting bail as shown or with straight bail links.

In Figure 16, a quick disconnect (which allows the drive unit 132 to be disconnected without specialized tools) has a tubular member 148 provided with keys 149 and an extension bearing a sealing element 150 which fits into a bore in a tubular member 151. The bore is formed with key slots 149ainto which the keys 149 fit. The tubular member 151 is externally threaded at 152. A threaded collar 153 mates with the threads 152 of tubular member 151 and has an internal ^" shoulder 153athat abuts a projection 154 on the tubular member 148 and thereby locks the assembly as a splined and sealed unit. The collar 153 is provided with lugs 155 which may be struck by a hammer to fully tighten the mating threads.

A novel gearbox structure incorporated into the hydraulically powered drive unit is shown in Figures 17 and 18. The central shaft 156 extends through and

projects above and below the housing 157. It is maintained in position in the housing by axially spaced upper and lower thrust bearings 158<ι and 158b_ which react both radial and axial loads in the shaft 156, above and below which there are upper and lower cylindrical roller bearings 159aand 159b_ which react radial loads and further steady the central shaft 156. The central shaft 156 is provided, midway between the thrust bearings 158a., 158b with male splines 161t). A driver gear 160 fits onto the central shaft 156 with a female splined hub 161 thereof mated with the male splines 161b and is retained axially in position on the central shaft 156 by means of upper and lower spacer lugs 156a,, 156b that fit on to the shaft 156 between the driven gear 160 and respective thrust bearings 156a, 156b. The housing 157 contains four pinions 162 spaced symmetrically about the central shaft 156 with their axes parallel thereto and with their teeth in mesh with teeth of the driven gear 160. The pinions 162 serve to transmit power from the four hydraulic motors 168 to the central shaft 156 via the driven gear 160. The pinions have upper and lower stub shafts 162a, 162b with the upper stub shaft 162 being supported in a cylindrical roller bearing 118 and with the lower stub shaft 162b being supported in a double-row roller thrust bearing 117 that is capable of reacting substantial radial and axial loadings. A retainer block 164 is attached to the end of the lower stub shaft 162b and is slotted to receive a drive input shaft of an oil pump 166 which is mounted on the cover 120. The upper stub shaft 162a.is formed with a bore in its end that defines a socket which has internal splines 163. An adaptor 167 fits into the socket with male splines on its outer surface meshing with the internal splines 163 and with female splines on its inner surface matching with a male

splined output shaft 168b of the hydraulic motor 168. This construction has the advantage that hydraulic motors 168 having output shafts 168b of different sizes may be fitted to the same drive unit 132 simply by selecting the fitting adaptors 167 of the appropriate internal and external dimensions but without the need to change any internal component of the gearbox. The central shaft 156 has a hole 173 bored end to end therethrough and is formed at each end with an oil-field thread 172 by which the shaft 156 may be connected to upper and lower parts of the drill string. The housing 157 is provided with double-row excluder seals 171 at its upper and lower end that make wiping contact with the central shaft 156. An oil to water heat exchanger 169 is installed within the housing 157 and cooling fluid is pumped through a connector 170 to cool the gearbox. Typically about 60 gallons (227 litres) is pumped through the heat exchanger 169 to cool the 55 gallons (208 litres) of gearbox oil in the housing 157. In Figures 19 and 20 a safety valve assembly fits between a portion of the central shaft 156 depending from the hydraulically powered drive unit 132 and the elevator link adaptor 134. It comprises a tubular member 177 formed with female and male oilfield screw threads at its upper and lower ends for connection to upper and lower portions of the drill string. Its central bore has a lower portion of larger diameter and an upper portion of smaller diameter. A step immediately above the upper portion seals an upper sealing element 176aagainst which there rotates a ball 174 of a ball plug valve having a bore 174a therethrough. The ball 174 is rotatable about a horizontal axis between a first position where the bore 174a _^ connects the upper and lower portions of the central bore of tubular member 177 and a second position (illustrated) in which the upper

and lower portions are isolated. The ball 174 and a lower sealing element 176b are held in place by a tubular locking plug 178 whose outer surface is threaded so that it can be rotated into engagement with an internally threaded region of the tubular member 177 via its castellated upper end. The ball 174 is formed with a drive slot 175 which receives a valve stem 185 housing a pinion gear 189 by which the ball 174 may be rotated. A rack 184 (Figure 20) in mesh with the pinion gear 189 actuates the ball 174 between its first and second positions. A shift yoke 181 of tubular form which is a sliding fit on the outer surface of the tubular member 177 and has an aperture 181a. in which the valve stem 185 and pinion gear 189 appear. The aperture 181a is spanned by the rack 184 which is axially directed and is attached to or forms part of the shift yoke 181. Also appearing in the aperture 181a_ is a stop block 190 attached to the tubular member 177 and carrying upper and lower threadedly adjustable stop pins 191a and 191b that act against upper and lower ends of the aperture 181a to limit the available axial travel of the shift yoke 181 to within an accurately adjusted range, so that correspondingly the first and second positions of the ball 174 can be set aligned with and perpendicular to the axis of the tubular member 177. For actuation of the shift yoke 181 in an upwards or downwards direction to open and close the valve, the outer surface of shift yoke 181 is formed with an annular slot 183 to which a cylinder bracket 180 is connected via bearing rollers 182 that are captive in the annular slot 183. Cylinders 179 have rods 188 projecting from their lower ends that are bolted to the cylinder bracket 180 and are attached to an overlying structure such as the hydraulically powered drive unit 132 at their upper ends by means of spacer nuts, 187b and locknuts 187a. The overlying

structure has posts 186 that are a sliding fit into tubular guide members 180a upstanding from the cylinder bracket 180 to prevent undesired rotation of the cylinder bracket 180. By appropriate adjustment of the lock and spacer units 187a and 187b a dead band or lost motion is created allowing the outer housing of cylinders 179 to move without actuating the cylinder rods 188. When the cylinders 179 are compressed they will move a short distance before locknuts 187a_ react against the underlying structure.

When the cylinders 179 are expanded they will move a short distance before the spacer nuts 187 react against the overlying structure. Thus when the cylinders 179 are actuated they have to move a short distance before the rods are activated which provides for infinite stroke adjustment. An operator can operate the valve described above to cut the mud flow through the hollow central shaft 156 of the hydraulically powered drive unit 132 on and off and the downward part of the hollow central shaft can be cut off by a remote operator to prevent well gasses from blowing out of the drill hole.

In Figures 21 - 26 a pipe wrenching device is shown which has a lateral opening for a drill pipe or other tubular workpiece between upper and lower pairs of pivoting die holders 197 which when closed hold the drill pipe against respective upper and lower die blocks 193a and 193b. A clamp cylinder 192 has a rod 192a which is fastened to the upper die block 193a. (Figure 24) by means of a stud 194. The clamp cylinder 192 has a trunnion 195 which fits into trunnion pivots 195a which in turn are pinned by tension pins 196 to one end of drag links 194a. The other ends of drag links 194a are pinned to upper pivoting die holders 197 which in turn are pivotally mounted to the upper die block 193a _^ by means of a pivot pin 198. The action of clamp cylinder

192 and rod 192a. is transmitted as a translational movement to the upper pivoting die holder 197 to open and close the opening for the drill pipe, but the pivots at the ends of the drag links 194a enable the die holders 197 to be rotated about a vertical axis relative to the cylinder 192. In operation, fluid pressure is fed to the piston side of cylinder 192, which action places drag links 194a in tension and rotates the die holders 197 inwardly against the drill pipe or other workpiece. Serrated jaws 199 in the die holders 197 increase the friction of the drill pipe or other workpiece, enabling the upper die block 193a and opposed die holders 197 to firmly clamp the drill pipe, An identical set of die block 193b and pivoting die holders 197b is located below the first set. The same clamping action takes place with the lower die block 193b and holder 197b as with the upper die block and holder. Breakout cylinders 200 are pivotally attached to the upper sections of the pipe wrenching device 137 at 201a_ and 201b. The opposite ends of the cylinders 200 are pivotally attached to the lower section of the pipe wrenching device 137. When the cylinders 200 are energized, opposite rotation occurs between the upper and lower sections of the pipe wrenching device 137, i.e., between upper and lower die blocks 193a_ and 193b_. It will be seen from Figures 23 and 24 that the upper die block 193a_ has a depending tongue 207 of T-section which is received in a corresponding groove in the top face of the lower die block 193b, the tongue and groove being on a radius 208 (Figure 22) and permitting relative rotation of the upper and lower die blocks 193a_, 193b without relative translational movement thereby maintaining engagement of the die holder halves 193a. and 193b during breakout operations. A male and female threaded tubular piece such as a junction between adjacent lengths of drill

pipe inserted within the jaws of the pipe-wrenching device 137 will become unscrewed.

In Figure 23, the clamp cylinder 192, drag links 194a and die holders 197 appear in their open retracted state in the upper half of the figure and appear in their closed extended state in the lower half of the Figure. In Figure 25, pipe wrenching device brackets 202 are shown firmly mounted to the lower die holders 193b. A pair of pivoting support 203 are each pivoted at one end to a respective one of the brackets 202 at a pin 205 and are each received at the other end in a respective saddle 204 which pivotally fits on to pivot pin 206 carried by support frame 135. The wrenching device retract cylinder 143 is shown connected between the support frame 143 and the retractible wrenching device 137 and when retracted moves the device from its well centring position (shown in solid lines) to its retracted position (shown in phantom) . In Figure 26, one of the breakout cylinders 200 is shown attached to the lower die block 193b at pivot pin 207a and is attached to the upper die block 193a _^ at pivot pin 201. Supply of fluid to one side of the breakout cylinder 200 retracts the rod into the breakout cylinder 200 and imparts a rotary motion to the upper die block 193a. In Figure 27, a drill pipe manipulator 138 of telescopic construction is shown and it enables drill pipe or other tubulars to be manipulated and positioned to align them with the centreline of the hollow central shaft 156 or the well centreline. The manipulator gimbal frame 139 is bored to accept an upper pivot pin 209 and a lower pivot pin 210 which are on the same centreline and from a split axle for pivotally supporting a rectangular section 211 of the manipulator 138. The section 211 slideably supports nested rectangular telescoping sections 216, 217 and 222. The back end of

each of the sections 216, 217 and 222 have roller brackets 212 attached thereto. The roller brackets 212 have roller shafts 213 carrying rollers 214. Shock- absorber pads 215 of resilient material are fitted to the brackets 212 at each location where they occur. Roller brackets 218 are attached to the forward ends of rectangular sections 216 and 217. A first ' stage retractor cylinder 219 fits within the sections 216, 217 and 222 and is attached at one end to the back of section 216 by pin 220 and at its opposite end to the rectangular section 222 at pin 221. When the rod of cylinder 219 is retracted the rectangular sections 216, 217 and 222 telescope together, establishing a "first stage" position. In Figure 28, a second stage retraction cylinder 235 is shown for retracting the pipe manipulator 138 away from the well centreline and connected at one end to the rectangular section 211 and at the other end to the rectangular section 216. A pin 213a connected to the rod of cylinder 235 has rollers 214a_. When the rod of cylinder 219 is extended, travel of the rectangular sections 216, 217 and 222 is limited by a stop rod 223 and stop blocks 224 on the front ends of sections 216, 217. A thrust bearing 225 supports rectangular section 211 and the upper and lower pivot pins 209, 210 are supported in radial bearings 226 and 227 A manipulator rotation cylinder 242 is attached to cylinder mounting 228. A pipe pickup bowl 230 is attached to the rectangular section 222 by a horizontally directed pivot pin 229 and spring 232 absorb, shock loads on the bowl 230. The pick up bowl

230 may, if desired, be rotated about the axis of pivot o pin 229 through an angle of 180 . During drilling it is often desirable to remove a single length of drill pipe from the string, and the pipe manipulator described

herein allows the loose end of the drill pipe to be picked up by an external hoisting line (not shown), fully horizontal. This facilitates removal of the pipe from the drill floor. The structure of the pickup bowl 230 is further apparent from Figures 29 and 30. A lateral opening 234 at the front of the bowl 230 allows entry of a length of drill pipe or other tubular element. A latch arm 231 is attached to the pickup bowl 230 adjacent the lateral opening 234 by means of a pivot pin 236. A latch cylinder 235a _^ is connected between the latch arm 231 and the bowl 230 and when extended rotates the latch arm 231 inwardly. The latch arm 231 is arranged to fail safe towards the closed position illustrated. In Figure 29 the bowl 230 appears in section and has a tapered seat o 237 (taper angle typically 18 ) which is preferably undercut and hard faced at 238.

The support frame 135 has rollers 240, 241 that appear in a partial view in Figures 31 - 33. An idler arm 242 is fitted with a roller bearing wheel 241 and is then attached by a pin 243 to a roller bracket 239. Cam follower roller bearing rollers 240 are attached to the idler arm 242 and the roller bracket 239. A coil spring 244 in compression beneath idler arm 245 allows the distance between the rollers 240 to vary and also absorbs shock loads. An adjustable bolt 246 enables the tension of coil spring 244 to be controlled. In Figure 32 which is a top view of the sub-assembly of Figure 31 the idler arm 242 is fitted with a second compression coil spring 244a and with a second adjustable bolt 246^. The idler arm 242, when present, is free to pivot about the pin 243 and the tension in the coil spring 244a _^ may be adjusted by the second adjustable bolt 246a_. The elevator link adaptor 134 is shown in

greater detail in Figure 34. A hollow tubular element 254 is formed with oil-pipe threads at upper and lower ends thereof for fitting between upper and lower portions of the drill string and is supported in a link adaptor housing 247 by means of a roller thrust bearing 250 which reacts both radial and axial loads and by a cylindrical roller bearing 253 that reacts radial loads and that is located above the thrust bearing 250. A spring cage 251 and compression springs 252 provide a cushioned pad between the thrust bearing 250 and a support shoulder of tubular element 254. Seals 255 and 258 in the link adaptor housing 247 make wiping contact with the tubular element 254 and isolate the working parts of the housing 247 from the exterior. A pair of link supports 249 is attached, e.g., by welding to opposed sides of the link adaptor housing 247 and are contoured to suit a standard elevator link. Link retainers 248 are attached by pivot pins 257 to the lower face of the housing 247 and can be attached to the link supports 249 by means of eyebolts 259 to hold the elevator links in place. If the housing 247 is externally restrained against rotation, the tubular element 254 is then free to rotate within the stationary housing.