TECHNIC AL FIELD

[0001 ] The present invention relates to, inter alia, a hose assembly, components of the hose assembly, a method of using the hose assembly and an apparatus including the hose assembly.

BACKGROUND ART

[0002] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Austfali a or in any other country.

[0003] The discussion below relates to air drilling, but it would be appreciated that the present invention is not limited to use in air drilling applications.

[0004] Air drilling typically involves pumping compressed air into a drill hole to lift drill cuttings from the bottom of the hole to the surface. A drill rig may be used for air drilling, and the drill rig may include a 'drill -string' for pumping compressed air to the bottom of the hole. The drill-string terminates at a drill-head which may incorporate air hammers or other equipment to aid in the drilling process. The air exiting the drill-string at the drill-head then flows upwardly through the hole in the annulus between the outside of the drill -string and the hole for in some cases, a casing lining the hole). As the air flows upwardly, loose drill cuttings from the bottom of the hole are entrained in the air-stream, and these drill cuttings are brought to the top of the hole before being discharged from the drill rig.

[0005] Air drilling typically becomes more effective as the velocity of the upwardly moving air increases, since this increases the likelihood that drill cuttings will be entrapped in the air stream. Typical air consumption for truck-mounted dual -rotary drilling rigs is in the vicinity of 3000 cubic feet per minute, with down-hole air pressures of 250 pounds per square inch.

[0006] Drill cuttings are typically discharged from the drill rig via a 'diverting tee', which directs the cuttings to exhaust out of an eight inch discharge pipe located just below the rotary head of the drill rig. As the rotary head of truck-mounted dual-rotary drilling rigs can typically travel througii eight metres of vertical movement, the discharge pipe similarly moves the same amount. When drilling or performing cleanout operations on the hole, drill cuttings may be ejected with velocities approaching 160 km/h at heights nearly 11 metres off the ground.

[0007] In view of the volume and speed of drill cuttings being ejected from the hole, significant environmental and safety improvements may be achieved through appropriate control over the discharge of the drill cuttings from these types of drill rig. Furthermore, there have been recent changes to legislation in countries such as Australia which have also resulted in an increased push towards such environmental and safety improvements. However, given that the discharge pipe of the drill rig may move through in excess of eight metres of travel, typical mechanisms for connection to the discharge pipe (such as mechanical sliders or fixed-end rotating joints) cannot be used.

SUMMARY OF INVENTION

[0008] Therefore, in one aspect it is an object of the present invention to provide an assembly that is connectable to a fluid outlet such as the discharge pipe of an air drill rig to enable control over the discharge of air and drill cuttings discharged from the rig. In another aspect, an object of the invention is to provide consumers with a useful or commercial choice.

[0009] In a first aspect, the present invention relates to a hose assembly including:

A hose;

A rotator enabling rotation of the hose as the hose coils; and

A hose guide for guiding the hose into at least one coil, wherein the hose guide includes an upwardly extending projection for encirclement by the hose as the hose is lowered onto the hose guide to thereby form the at least one coil.

[0010] Furthermore, in a second aspect the present invention relates to a hose assembly including:

An extensible hose having an inlet and an outlet for fluid, and movable between a substantially coiled arrangement and less or uncoiled arrangement;

A rotator coupling connected to the hose, especially for enabling the hose to move between the less or uncoiled arrangement to the substantially coiled arrangement; and

A hose guide located below the hose inlet for guiding the hose into the substantially coiled arrangement and for supporting at least one coiled length of the hose.

[0011] By 'substantially coiled arrangement', it is meant that there is at least one coiled length of hose, but preferably two, three or possibly more coils supported by the hose guide. [0012] By 'less or uncoiled arrangement', it is meant that there are fewer or no coiled length of hose supported by the hose guide.

[0013] Advantageously, the hose assembly of the first and second aspects of the present invention may be conneetable to a fluid outlet such as the discharge pipe of an air drill rig to enable control over the discharge of air and drill cuttings discharged from the rig. The term ' control ^' refers to the ability to direct the discharging product to a suitable location, rather than to an ability to throttle the discharge,

[0014] In particular, the inlet of the hose of the first and second aspects may be connected to a fluid outlet such as the discharge pipe of an air drill rig. As the fluid outlet moves downwardly, this may lower the hose onto the hose guide which guides the hose to form at least one coil.

[0G15J _. Coili ng of the hose may prevent kinking of the hose (kinking of the hose may cause significant safety problems). Furthermore, the coiling of the hose may result in rotational twisting (torsion) of the hose along its length.,: and this twisting may be ameliorated by the rotator (or rotator coupling) which enables rotation of the hose as the hose forms at least one eoil (or as the hose adopts a substantially coiled arrangement).

[0016] Whilst the hose assembly of the first and second aspects may be particularly suited for use in air drilling operations, the assembly may be used to move any fluid or flowable media from one translatable location (in any plane and direction, but especially in a substantially vertical plane) to another location which is especially fixed.

[0017] One or more components of the hose assembly may be provided separately (such as in kit form), or the hose assembly may be assembled for use.

[0038] The hose may be of any suitable size, length, shape or type. In one embodiment, the hose is resistant, to kinking. The walls of the hose may be made of any suitable material. In one embodiment, the walls of the hose are made from a polymer, especially rubber.

[0019] The walls of the hose may include a reinforcer. The reinforcer may include a coil, especially a metal coil, more especially a wire coil or helix, most especially a steel wire coil or helix. The wire reinforcer may be from 1 mm to 10 mm thick, especially from 2 mm to 8 mm thick, more especially from 4 ram to 6 mm thick. The reinforcer may also include a high tensile synthetic, especially a high tensile synthetic polymer. The high tensile synthetic may be 2, 3, 4, 3, or 6 ply, especially 3, 4 or 5 ply, most especially 4 ply. The reinforcer may extend along the length of the hose. The reinforcer may be embedded in the walls of the hose or the reinforcer may abut the inside or outside wall of the hose. The reinforcer may be or include a whipsock. The reinforcer may be or include a burst sheath/sleeve. The reinforcer may improve the structural integrity and/or kink resistance of the hose.

[0020] The walls of the hose may be of any suitable thickness. In one embodiment, the walls of the hose may be from 5 mm to 100 mm thick, especially from 10 mm to 80 mm thick or from 10 mm to 60 mm thick, more especially from .15 mm to SO mm thick or from 20 mm to 45 mm thick, most especially from 25 mm to 40 mm thick or from 28 mm to 37 mm thick or about 32 mm thick.

[0021] The inner diameter of the hose may be from 25 mm to 500 mm, especially from 50 mm to 400 mm or from 100 mm to 350 mm, more especially from 150 mm to 310 mm or from 150 mm to 250 mm, most especially from 180 mm to 220 mm or about 204 mm. The outer diameter of the hose may be from 30 mm to 600 mm, especially from 80 mm to 500 mm or from 150 mm to 400 mm, more especially from 180 mm to 350 mm, most especially from 21.0 mm to 260 mm or about 235 mm.

[0022] The hose may have a pressure rating of from 1 atm to 20 atm, especially from 2 atm to 15 atm or from 5 atm to 15 atm, most especially about 10 atm (about 150 psi). The hose may have a bending radius of from 500 mm to 6000 mm, especially from 1000 mm to 6000 mm or from 1200 mm to 5000 mm, more especially from 1200 mm to 4000 mm or from 1500 mm to 3500 mm, most especially from 1900 mm to 2700 mm. The hose may have a weight of from 1 kg/m to 50 kg/m, especially from 4 kg/m to 40 kg/m or from 8 kg/m to 35 kg/m, more especially from 12 kg/m to 30 kg/m, most especially from 12 kg/m to 25 kg/m or from 15 kg/m to 20 kg/m.

[0023] The hose may be of any suitable length. In one embodiment, the hose is from 1 m to 40 m long, especially from 1 m to 30 m long or from 1 m to 20 m long, more especially from 3 m to 15 m long or from 4 m to 12 m long, most especially from 6 m to 10 m long or about 8 m long.

[0024] The hose may be a slurry hose. A suitable slurry hose may be a slurry suction and discharge hose sold by the company Sunf!ex® (catalogue numbers SSDI 50 and SSD150 - COR).

[0025] The hose has an inlet and outlet ('ends'), and these may be made of any suitable material. Tn one embodiment, the ends of the hose are made from metal, especially steel. One or both ends of the hose may be swaged. A swaged hose end may permit connection of the hose to another component using a hydraulic press (which may result in steel clamped on steel, which may provide a strong, tight connection). One or both ends of the hose may include a barb (rib). A barbed hose end may permit connection of the hose to another component with a hose clamp. One or both ends of the hose may include a flange including a plurality of apertures. The apertures in the flange may permit the flange to be fastened to another component using fasteners, especially bolts.

[0026] Advantageously, the hose used in the present invention need not have a 'memory' (i.e. be capable of independently coiling itself).

[0027] In one embodiment, the hose is movable between a substantially coiled arrangement and less or uncoiled arrangement.

[0028] The rotator may be a rotator coupling. The rotator (or rotator coupling) may be connected to an end of the hose or anywhere between the ends of the hose, in one embodiment, the rotator (or rotator coupling) is connected to the inlet of the hose, and the rotator (or rotator coupling) is further connectable to a fluid outlet/fluid discharger. The fluid discharger may be a discharge pipe of an air drill rig (especially a dual-rotary air drilling rig) or other type of drill rig utilising fluid in the form of a gas or liquid, or possibly both. In another embodiment, the rotator (or rotator coupling) is located intermediate the inlet and outlet of the hose, and the rotator (or rotator coupling) may be located towards the inlet of the hose (which is connectable to a fluid discharger). The outlet of the hose may be rotationally fixed (this may prevent the hose from twisting about its axis at this end).

[0029] The rotator (or rotator coupling) may be of any suitable design and shape, and function in any suitable way. In one embodiment, the coupling has two opposed ends that swivel relative to one another. The rotator coupling may have a flow passage extending between the opposed ends for discharged fluid. Exemplary swivel couplings/connectors are sold by the company Chiksan®.

[0030] The rotator coupling flow passage for discharge fluid may have an inner diameter of from 25 mm to 500 mm, especially from 50 mm to 400 mm or from 100 mm to 350 mm, more especially from 150 mm to 310 mm or from 150 mm to 250 mm, most especially from 180 mm to 220 mm or about 204 mm.

[0031] The rotator coupling may have a first end and a second end of any suitable design. The first and/or the second end may include a body and a flange extending from the body that includes a plurality of apertures. Each body may be of any suitable size, shape and design. The apertures in the flange may permit the flange to be fastened to another component (such as to an end of the hose) using fasteners, especially bolts. The flange may be integrally formed with the first and/or second end of the rotator coupling, or the flange may be fastened to the first and/or second end of the rotator coupling in any suitable way. In one embodiment, the flange is fastened to the first and/or second end of the rotator coupling by welding.

[0032] The first and second ends/bodies may each be in the form of a ring (or sleeve), especially a flanged ring (or sleeve). The ends/bodies may be in the form of an inner ring and an outer ring. The rotator coupling may include an inner ring and an outer ring, wherein the inner ring and outer ring are rotatable relative to each other in a concentric arrangement about a common axis of rotation, and the discharge fluid may flow along the common axis of rotation. The overlapping portion of the inner ring and outer ring may be from 10 mm to 250 mm, especially from 40 mm to 200 mm or from 60 mm to 180 mm, more especially from 80 mm to 150 mm or from 100 mm to 130 mm, most especially about 115 mm.

[0033] The rotator coupling may include at least one seal so as to render the coupling fluid tight, such as an O-ring. The rotator coupling may include one or more seals, for example such as O-rings extending circumferentially between the inner and outer rings.

[0034] The rotator coupling may include ball bearings, including sets of ball bearings, and these may be located within one or more grooves extending circumferentially along the inner and outer rings.

[0035] Preferably, two sets of ball bearings and two seals extend between the inner and outer rings so as to enable the rings to rotate relative to one another in a fluid tight manner.

[0036] The rotator (or rotator coupling) may be capable of withstanding a pressure of at least 200 psi, especially of at least 250 psi or of at least 300 psi, more especially at least 350 psi. The rotator may be capable of withstanding a load of at least 29 kN, especially at least 44 kN, more especially at least 58 k.N. The rotator (or rotator coupling) may be capable of withstanding an axial, load of at least 3 tonne.

[0037] The rotator (or rotator coupling) may have a length of up to 400 mm, especially of up to 350 mm. more especially of up to 300 mm, most especially of up to 250 mm or about 250 mm. The rotator (or rotator coupling) may have a length of greater than 100 mm, especially greater than 150 mm, more especially greater than 200 mm.

[0038] The hose assembly may include one rotator (or rotator coupling) or a plurality of rotators (or rotator couplings), such as two rotators (or rotator couplings); However, the hose assembly may especially include only one rotator (or rotator coupling).

[0039] Advantageously as the hose coils and uncoils, the hose will twist along its length. The presence of the rotator (or rotator coupling) ameliorates this twisting (torsion) to reduce strain or stress on the hose and therefore the hose assembly.

[0040] The hose guide may be of any suitable size, shape and construction, and made of any suitable material or materials. In one embodiment, the hose guide includes an upwardly extending projection. In another embodiment, the hose guide is located below the hose inlet. The hose guide may be for supporting at least one coiled length of the hose.

[0041] In one embodiment the upwardly extending projection is for encirclement by the hose as the hose is lowered onto the hose guide to thereby form the at least one coil. As used herein, the term "encirclement" means that the hose coils around the projection; the hose need not coil around the projection in circular manner.

[0042] The upwardly extending projection may be of any suitable shape. In one embodiment, the upwardly extending projection has a circular, ovoid or elliptical cross section, especially an elliptical cross section. As the hose coils it may follow the wall of the upwardly extending projection. Therefore, if the curve of the wall of the projection is too tight then this may encourage kinking of the hose. In one embodiment, the curvature of the wall of the projection does not exceed 8 times (or 10 times) the diameter of the hose.

[0043] The upwardly extending projection may have a base and an apex. The upwardly extending projection may generally narrow or taper in a direction from the base to the apex. In one embodiment the upwardly extending projection is generally conical in shape. In preferred embodiments, the hose guide is in the form of a cone or circular ramp narrowing towards the apex.

[0044] The apex of the upwardly extending projection may be eccentrically positioned relative to the centre of the base. In one example, if the hose assembly is used as part of a drill rig apparatus, the apex of the upwardly extending projection may be eccentrically positioned towards the mast of the drill rig.

[0045] The lowering of the hose onto the hose guide (and the raising of the hose from the hose guide) may be in a vertical direction, a substantially vertical direction, or at an oblique angle to the vertical. However, if the hose is lowered onto the hose guide (or raised from the hose guide) at an oblique angle to the vertical, the hose must be lowered sufficiently vertically for the hose to encircle the upwardly extending projection as it is lowered. Eccentrically positioning the apex of the projection may allow the hose to be lowered at more of an oblique angle to the vertical (i.e. with a greater lateral movement). This may be necessary as if the hose assembly is connected to a drill rig, the mast of the drill rig typically moves vertically. Some lateral movement of the hose therefore may be necessary as the hose is lowered onto the hose guide, as the hose guide cannot be positioned directly underneath the mast.

[0046] The cross sectional area of the upwardly extending projection may decrease at the same rate towards the apex, or the cross sectional area of the upwardly extending projection may include two or more portions which decrease the cross sectional area towards the apex at different rates. Therefore, the upwardly extending projection may include a first portion at the base of the projection and a second portion towards the apex, wherein the first portion has a steeper wall than the second portion. A first portion having a steep wall may be advantageous as this may allow the hose to coil about the projection in a predictable way. A second portion having a less steep wall may be advantageous to assist in collecting the hose. The apex of the projection may be substantially planar.

[0047] The projection may be fixed in position relative to the hose. In one embodiment, the projection is non-rotatable.

[0048] The projection may be made of any suitable material. In one embodiment, the projection is made from metal, especially from steel, more especially from carbon steel. The projection may be of any suitable thickness. In one embodiment, the projection is from 1 mm to 10 mm thick, especially from 1 mm to 8 mm thick or from 2 mm to 6 mm thick, most especially about 4 mm thick.

[0049] The hose guide may include a guiding perimeter such as at least one baffle for further guiding the hose into at least one coil. The at least one baffle may extend in an arc around the projection.

[0050] In a first exemplary embodiment, the baffle may be a wall or a plurality of walls. In this case, the baffle may be a wall or plurality of walls extending in an arc around the projection. The or each wall may be of the same height or variable height. When the apex is eccentrically positional relative to the centre of the base, the or each wall may be of lower height proximate to the apex than distal to the apex. Advantageously, as the hose coils around the projection each successive coil may be positioned above the last If the apex of the projection is eccentrically positioned, then at the side of the projection distal to the apex each successive coil may be positioned inside the last; however at the side of the projection proximate to the apex each successive coil may be positioned outside the last. Consequently, it may be advantageous to provide a wall of lower heigh I proximate to the apex to provide space for the hose to coil .

[0051] The or each wall may be made of any suitable material. In one embodiment, the or each wall is made from metal, especially from steel, more especially from carbon steel. The or each wail may be of any suitable thickness. In one embodiment, the or each wall is from 1 mm to 10 mm thick, especially from 1 mm to 8 mm thick or from 2 mm to 6 mm thick, most especially about 4 mm thick.

[0052] In a second exemplary embodiment, the baffle is a plurality of posts. The posts may especially be metal posts. The posts may be positioned around the projection. The posts may be extendible. However, it may be preferable for the baffle to be a wall or a plurality of walls rather than a plurality of posts, as the hose may vibrate when the hose assembly is in use and if the hose abuts a post (rather than a wall) it may be more likely to wear. The plurality of posts may be made of any suitable material. In one embodiment, the plurality of posts may be made from metal, especially from steel.

[0053] The hose guide may include a base. The projection and the at least one baffle may be mounted relative to (especially mounted to) the base.

[0054] Advantageously, the hose guide may permit a hose to be coiled around the projection widhout the use of a spool or any 'self-coiling memory' in the hose (i.e. a hose which is manufactured with a memory or 'set' so that it reverts to a coiled position once a displacing force has been removed). When heavier hoses are used, once the hose is raised from the hose guide the hose effectively straightens due to the weight of the hose and the rotator.

[0055] Therefore, in a third aspect the present invention relates to a hose guide for guiding a hose into at least one coil or into a substantially coiled arrangement, wherein the hose guide includes an upwardly extending projection for encirclement by the hose as the hose is lowered onto the hose guide to thereby form at least one coiled length of hose/the at least one coil. Features of the third aspect of the present invention may be as described for the first and second aspects.

[0056] In a fourth aspect, the present invention relates to an apparatus for controlling a fluid discharge, the apparatus including the hose assembly of the first or second aspects of the present invention. Features of the hose assembly defined in the fourth aspect of the present invention may be as defined for the first and second aspects of the present invention.

[0057] In one embodiment, the apparatus includes a fluid outflow/fluid discharger. The fluid outflow/fluid discharger may be the discharge pipe of a drill rig, especially an air drill rig, more especially a dual-rotary air drilling rig. fn this embodiment, the hose inlet may be connected to the fluid outflow/fluid discharger, or the hose inlet may be connected to a first end of the rotator (or rotator coupling), and the second end of the rotator (or rotator coupling) is connected to the fluid outflow/fluid discharger.

[0058] The term "fluid" as used herein may include any liquid or gas, and especially includes a gas (such as air). Solids may be suspended in the fluid. For example, the fluid may be a gas within which is suspended solids (especially particulates). The suspended solids may have a particle size of up to 250 mm, especially of up to 200 mm, more especially of up to 180 mm.

[0059] In another embodiment, the apparatus includes a degasser. The degasser may include a vessel, a fluid inlet and/or a fluid outlet. The fluid outlet may include a gas outlet and a non-gaseous outlet.

[0060] Therefore, in one embodiment the present invention provides an apparatus for controlling a fluid discharge, the apparatus including:

Λ degasser including an inlet for receiving a discharged fluid, and an outlet at which the discharge of the fluid is controlled; and

The hose assembly of the first or second aspects of the present invention, wherein the hose outlet is connected to the degasser inlet.

[0061] The degasser may include a filter (especially a screen or a metal screen, more especially a steel screen, most especially a stainless steel screen) located within the vessel for filtering out non-gaseous components entrained in the gas such that they cannot escape through the gas outlet. The filter may prevent liquid entrapped solids and mist from exiting the degasser vessel through the gas outlet. The degasser may include a filter inspection platform, which may include a sprung-loaded safety gate and/or a retractable ladder.

[0062] The degasser may include a flushing system, which especially may be located at the lower region of the vessel. The flushing system may be used in conjunction with, but not limited to, the degasser outlet (especially the non-gaseous outlet as discussed below). The flushing system may include at least one jet of any suitable size, shape and construction. The flushing line may include an inlet for connection to a water hose, especially a jetting hose, more especially a 2 inch diameter jetting hose. The flushing line may be for washing away sediment captured in the vessel.

[0063] The outlet of the hose may be connected to the degasser fluid inlet. The outlet of the hose may be rotationally fixed (unable to rotate or non-rotatable). The degasser fluid inlet may be located at a lower end of the vessel, and the inlet may be for introducing a fluid stream into the vessel The fluid inlet may be for introducing the fluid stream into the vessel at a reduced velocity relative to velocity of the fluid in the hose. For example, a downstream (outflow) end of the fluid stream inlet may be of greater diameter or cross sectional area than an upstream (inflow) end of the fluid stream inlet. This change to a larger diameter/cross-sectional area will result in the fluid stream velocity slowing as it passes through the degasser inlet, in one embodiment, the degasser inlet is a manifold, especially a tangential entry manifold, more especially an expanded tangential entry manifold.

[0064] The degasser may include a gas outlet, which especially may be located at an upper end of the vessel, and a non-gaseous outlet which especially may be located at a lower end of the vessel. The gas outlet may be an opening in the upper end of the vessel. The non-gaseous outlet may be in the form of a discbarge chute. The degasser may include a pressure relief system for venting gas when gas pressure within the vessel exceeds a predetermined pressure.

[0065] The degasser may separate the gas from non-gaseous components in the fluid stream in any suitable way. In one embodiment, the degasser is an impingement separator. Nongaseous components can be separated from gas by way of gravity segregation and/or centrifugal action, for example. The degasser may be a poor boy separator. The degasser may be an open- bottom vertical mud gas separator and the outlet for non-gaseous components may be sealed by way of a liquid seal. The vessel may extend vertically or horizontally. In one embodiment, the vessel is substantially cylindrical and substantially vertically oriented, and is of sufficiently large diameter so as to handle large volumetric flow rates (such as flow rates exceeding 200 L per second). A suitable degasser is described in WO 2012/006685.

[0066] if the degasser is an impingement separator, the degasser may further include one or more impingement plates or baffles located within the vessel for effecting separation of gas from non-gaseous components as these move toward the lower end of the vessel. If employing centrifugal action, the degasser may include one or more baffles for disrupting swirling flow of the non-gaseous (fluid) components in the lower end of the vessel. The degasser may include internal baffle plates designed to change the direction of liquids and solids falling to the lower end of the vessel. The degasser may include a replaceable impingement plate held in position on the vessel using locators. The degasser may include a solids chute located at the lower end of the vessel and angled to direct solids away from the non-gaseous component outlet.

[0067] The hose assembly and the degasser may be mounted on a platform, such as a skid or trailer (especially a pig-type trailer) for transport. The platform may have lifting fixtures for cranes and hoists. The platform may have safety handrails, platforms etc.

[006S] In a fifth aspect, the present invention relates to a hose guide when used in the hose assembly of the first or second aspects of the present invention, or a hose guide when used in the apparatus of the fourth aspect of the present invention.

[0069] In a sixth aspect, the present invention relates to a hose when used in the hose assembly of the first or second aspects of the present invention, or a hose when used in the apparatus of the fourth aspect of the present invention.

[0070] In a seventh aspect, the present invention relates to a rotator (or rotator coupling) when used in the hose assembly of the first or second aspects of the present invention, or a rotator (or rotator coupling) when used in the apparatus of the fourth aspect of the present invention.

[0071 ] In an eighth aspect, the present invention relates to a degasser when used in the apparatus of the fourth aspect of the present invention

[0072] Features of the fifth to seventh aspects of the present invention may be as described for the first or second aspects of the present invention. Features of the fifth to eighth aspects of the present invention may be as described for the fourth aspect of the present invention.

[0073] in a ninth aspect, the present invention relates to a method of coiling a hose using the hose assembly of the first or second aspects of the present invention or the apparatus of the fourth aspect of the present invention, the method including the step of:

Lowering the hose onto the hose guide to thereby form at least one coil.

[0074] In a tenth aspect, the present invention relates to a method of uncoiling a hose using the hose assembly of the first or second aspects of the present invention or the apparatus of the fourth aspect of the present invention, the method including the step of: Raising the hose from the hose guide to thereby uncoil the hose.

[0075] Features of the ninth and tenth aspects of the present invention may be as described for the first, second or fourth aspects of the present invention.

[0076] In an eleventh aspect, the present invention relates to a method of controlling a fluid discharge, the method including passing a fluid through the apparatus of the fourth aspect of the present invention. Features of the eleventh aspect of the present invention may be as described for the fourth aspect of the present invention.

[0077] In an twelfth aspect, the present invention relates to a method of assembling the apparatus of the fourth aspect of the present invention. The method may include the step of connecting the inlet of the hose to a fluid outflow/fluid discharger (which may be the discharge pipe of a drill rig, especially an air drill rig, more especially a dual-rotary air drilling rig). The method may alternatively include the steps of connecting the inlet of the hose to the first end of the rotator (or rotator coupling), and/or connecting the second end of the rotator (or rotator coupling) to the fluid outflow/fluid discharger. The method may also include the step of connecting the outlet of the hose to the degasser, especially to the degasser fluid inlet. Features of the twelfth aspect of the present invention may be as described for the fourth aspect of the present invention.

[0078] Any of the features described herein can be combined in any combination with any one or more of the other features described herein within the scope of the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0079] Examples of the invention will now be described by way of example with reference to the accompanying figures, in which:

[0080] Figure 1 is an isometric view of a first example apparatus, in which the hose is raised from the hose guide;

[0081 ] Figure 2 is an isometric view of the example apparatus of Figure 1 , in which the hose is lowered onto the hose guide;

[0082] Figure 3 is a perspective view of a second example apparatus;

[0083] Figure 4 is a perspective view of the apparatus of Figure 3;

[0084] Figure 5 is a perspective view of an example rotator, in which a portion of the wall of the rotator is cut-away;

[0085] Figure 6 is a cross-sectional view of the example rotator of Figure 5;

[0086] Figure 7 is a perspective view of the inner ring of the rotator of Figure 5;

[0087] Figure 8 is a cross-sectional view of the inner ring of Figure 7;

[0088] Figure 9 is a perspective view of the outer ring of the rotator of Figure 5; and

[0089] Figure 10 is a cross-sectional view of the outer ring of Figure 9.

[0090] Preferred features, embodiments and variations of the invention may be discerned from the following Description which provides sufficient information for those skilled in the art to perform the invention. the following Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way.

DESCRIPTION OF EMBODIMENTS

[0091] Exemplary hose assemblies, apparatuses and rotators (in the form of rotator couplings) of the invention will now be discussed with reference to Figures 1 to 10. In the figures, like reference numerals refer to like features.

[0092] Figures 1 to 4 illustrate two exemplary hose assemblies 1. The hose assembly 1 includes a hose 2, a rotator coupling 4, and a hose guide 6. The hose guide 6 includes an upwardly extending projection 60. As the hose 2 is lowered onto the hose guide 6, the hose encircles the upwardly extending projection 60 to thereby form at least one coil.

[0093] The hose 2 is resistant to kinking. The hose in the examples of Figures 1 and 2, and Figures 3 and 4 includes a reinforcer in the form of a steel wire coil or helix. The wire in the wire coil or helix is from 4 mm to 6 mm thick, extends along the length of the hose 2 and is embedded in the walls of the hose. The hose may also include a whipsock and/or a burst sheath/sleeve reinforcer.

[0094] The inner diameter of the hose 2 may be about 204 mm (8 inches). The outer diameter of the hose 2 may be about 235 mm. The walls of the hose 2 may have a thickness of about 32 mm. The walls of the hose 2 may be made from rubber. The hose 2 may have a pressure rating of about 10 atm (about 150 psi). The hose 2 has a bending radius of from 1900 mm to 2700 mm, and a weight of from 15 kg/m to 20 kg/m. The hose 2 is about 8 m long. The hose is a slurry hose. [0095] The hose 2 has a first inlet end 22 and a second outlet end 24.

[0096] The rotator coupling 4 includes a first end 42 and a second end 44, each in the form of a flanged body, and more particularly a flanged ring. The rotator coupling first end 42 is coupled to the hose inlet end 22. The rotator coupling second end 44 is connectable to a fluid outflow/fluid discharger, such as the discharge pipe of a drill rig. Therefore, the rotator coupling 4 enables rotation of the hose at the hose inlet end 22. As the hose 2 coils and uncoils, the hose 2 will twist along its length. The rotator coupling 4 ameliorates this twisting to reduce strain or stress on the hose 2 and the hose assembly I, as well as to components connected to the hose such as a fluid discharger and the inlet of a degasser.

[0097] An exemplaty rotator coupling 4 is illustrated in Figures 5 to 10. This rotator coupling 4 has an inner diameter/internal flow passage diameter of about 204 mm (about 8 inches). The first and second ends 42, 44 include a flange 43, 45 including a plurality of apertures. The apertures in the flange 43, 45 permit the flange to be bolted to another component (such as to the hose inlet end 22).

[0098] The rotator 4 also includes an inner ring 46 and an outer ring 47, and the flanges 43, 45 are welded to the rings 46, 47. The rings 46, 47 are rotatable relative to each other. A portion 48 of the inner ring 46 overlaps with a portion 49 of the outer ring 47. These overlapping portions 48, 49 extend about 115 mm along the length of the rotator 4. Intermediate the overlapping portions 48, 49 are located two O-rings 50 and a plurality (or two sets) of ball bearings 51 which are located in a groove in the portions 48, 49.

[0099] The rotator 4 is capable of withstanding a pressure of at least 350 psi. The rotator 4 is capable of withstanding an axial load of at least 3 tonne. The rotator 4 has a length of about 250 mm.

[00100] The upwardly extending projection 60 in Figures 1 to 4 has an elliptical cross section, and as the hose 2 coils it generally follows the wall of the upwardly extending projection 60. The curvature of the wall of the projection 60 does not exceed 8 to 10 times the diameter of the hose 2. This curvature lessens the likelihood that the hose 2 will kink.

[00101] The projection 60 is tapered towards its apex 62. The apex 62 is substantially planar and is eccentrically positioned relative to the centre of the base 68. An eccentrically positioned apex 62 allows the hose 2 to coil around the projection 60 even if the hose 2 is lowered at an oblique angle to the vertical (which would be the case in air drilling operations). The projection 60 includes a first portion 64 at the base 68 of the projection 60 and a second portion 66 towards the apex 62. The first portion 64 has a steeper wall than the second portion 66. The changing steepness in the wall of the projection 60 may assist the hose 2 to coil in a predictable way.

[00102] The projection 60 is non-rotatable and is made from 4 mm thick carbon steel. The projection 60 is mounted on a base 70.

[00103] The hose guide 6 also includes at least one baffle 72 for guiding the hose 2 into the at least one coil. The at least one baffle 72 is mounted to the base 70.

[00104] In the assembly 1 illustrated in Figures 1 and 2, the baffle is a wall 72 extending in an arc around the projection 60. The wall 72 has a lower height proximate to the apex 62 than distal to the apex 62. This may provide space for the hose 2 to coil, as discussed above. The wall 72 is made from 4 mm thick carbon steel.

[00105] In the assembly 1 illustrated in Figures 3 and 4, the baffle is a plurality of posts 72 positioned around the projection 60. The posts 72 are extendible and are made from steel.

[00106] The assembly 1 illustrated in Figures I to 4 forms part of an apparatus 100 for controlling a fluid discharge. The apparatus 1.00 also includes a degasser 110. The apparatus 100 of Figures 1 to 4 is suitable for use in controlling the fluid discharge from a dual -rotary air drilling rig. The fluid may be a gas within which is suspended particulates having a particle size of up to 180 mm.

[00107] The degasser 110 includes a vessel 112, and a filter 114 (in the form of a stainless steel screen) for filtering out non-gaseous components entrained in the gas. The degasser 110 also includes a fluid inlet 116 which is coupled to the hose outlet 24. The fluid inlet 116 is in the form of an expanded tangential entry manifold.

[00108] The degasser 110 includes a gas outlet 118, which is an opening in the upper end of the vessel. The degasser 110 also includes a non-gaseous outlet 120 at. the lower end of the vessel.

[00109] The degasser 11.0 also includes a filter inspection platform 122, having a sprung- loaded safety gate and a retractable ladder. The degasser 110 also includes a flushing system 124 having an inlet for connection with a 2 inch diameter jetting hose. The flushing system 124 is for washing away sediment captured in the vessel 112.

[00110] The apparatus 100 is mounted on a platform (or base) 70 for transport. [00111] Advantages of the preferred, aspects of the present invention include:

- The hose 2 (and apparatus 100 more generally) is connectable to the discharge pipe of an air drill rig. The discharge pipe typically moves through in excess of eight metres of travel, and the hose assembly 1 and apparatus 100 can accommodate this movement.

- As the discharge pipe moves vertically, the hose 2 coils and uncoils itself at the hose guide 2. No spools or other mechanical intervention is required to drive the hose 2 into coils.

- The rotator 4 ameliorates stress or strain placed upon the hose due to rotational twisting (torsion) of the hose 2 as it coils and uncoils.

- The hose 2 used in the hose assembly 1 need not have any memory (it need not be capable of coiling itself).

• The hose 2 may be raised and lowered at an oblique angle from the hose guide 6 due to the eccentrically positioned apex 62 relative to the centre of the base. This is necessary in air drilling operations as the mast of the drill rig cannot be located vertically above the upwardly extending projection.

- When the hose assembly 1 forms part of the apparatus 100, the apparatus 100 is capable of safely discharging significant amounts of fluid (in excess of 200 L per second).

[00112] Reference throughout this specification to 'one embodiment' or 'an embodiment' means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases 'in one embodiment ^* or 'in an embodiment' in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[00113] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. ft is to be understood that the invention is not limited to specific features shown or described since the means herein described includes preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.