Apparatus and method for forming an enlarged underground arcuate bore and installing a conduit therein

A method for drilling an arcuate underground pilot bore hole along a predetermined arcuate path in one direction of travel between two surface locations defining an entrance and an exit, and then enlarging the pilot bore hole in an opposite direction of travel between the surface locations to receive a production conduit therein, the bore hole being drilled by a drill pipe string of connected pipe sections including a leading drill pipe section of a strength less than the strength of at least the majority of the remaining pipe sections;

• said method comprising the steps of:
• providing thrusting means at the surface entrance location to advance the drill string and small diameter leading drill pipe section with a drill bit thereon in one direction of travel along the arcuate path;
• circulating drilling fluid through said drill string during the drilling operation;
• removing the small diameter leading drill pipe section from the drill pipe string after exit from the exit location;
• attaching a reamer and production conduit connected thereto to the drill string at the exit location after the small diameter leading pipe section has been removed;
• pulling the drill string, reamer, and production conduit along the pilot bore hole from the exit location to the entry location in an opposite direction of travel with the reamer forming an enlarged opening to receive the production conduit;
• rotating said drill string and reamer during pulling thereof;
• and
• circulating drilling fluid through said drill string during the reaming operation.

A method of drilling an arcuate underground pilot bore hole along a predetermined path between two spaced surface locations utilizing a spud bit on a leading drill pipe section of a drill string with discharge nozzle means in a leading front face of the bit directly adjacent to the formation to be excavated and eroded;

• said method comprising the steps of:
• advancing the leading drill pipe section of the drill string having the spud bit thereon with said nozzle means in said front face positioned directly adjacent the formation to be excavated from a surface entrance location to the surface exit location;
• discharging drilling fluid from said nozzle means in a jet with the center of the drilling fluid jet being discharged offset from the longitudinal axis of the leading pipe section to aid in guiding the pipe string along the predetermind arcuate path;
• and
• providing a predetermined partial rotation of the leading drill pipe section and the spud bit thereby to change the direction of offset of said nozzle means and the deviation of the leading pipe section.

A method of drilling an arcuate underground pilot bore hole along a predetermined path between two spaced surface locations utilizing a spud bit on a leading drill pipe section of a drill string with discharge nozzle means in a leading front face of the bit directly adjacent to the formation to be excavated and eroded;

• said method comprising the steps of:
• advancing the leading drill pipe section of the drill string having the spud bit thereon with said nozzle means in said front face positioned directly adjacent the formation to be excavated from a surface entrance location to a surface exit location;
• discharging drilling fluid from said nozzle means in a jet with the center of the drilling fluid jet being discharged offset from the longitudinal axis of the leading pipe section to aid in guiding the pipe string along the predetermined arcuate path;
• providing a predetermined partial rotation of the leading drill pipe section and the spud bit thereby to change the direction of offset of said nozzle means and the deviation of the leading pipe section;
• providing thrusting means at the surface entrance location to advance the drill string and spud bit thereon in a direction of travel along the arcuate path from an entrance opening to an exit opening;
• attaching a reamer to the drill string at the exit location;
• pulling the drill string and reamer back through the pilot bore hole from the exit opening to the entrance opening in an opposite direction of travel with the reamer forming an enlarged opening;
• pushing the reamer back through the reamed hole from said entrance opening to said exit opening;
• connecting the production conduit to the reamer at said exit opening;
• and
• then pulling the reamer and production conduit back through the reamed opening from said exit opening to said entrance opening for installing the production conduit within the enlarged reamed hole.

A method of boring an arcuate underground pilot bore hole along a predetermined path between two spaced surface locations in a single boring operation of a single constant diameter utilizing a drill bit on a leading drill pipe section of a lightweight drill string formed of a flexible high strength non-magnetic alloy material;

• said method comprising the steps of:
• advancing the drill string having the drill bit thereon from a surface entrance location to a surface exit location to form a pilot bore hole of a single constant diameter;
• providing means on said drill bit to permit a predetermined deviation of the leading pipe section upon a partial rotation of the leading pipe section a predetermined amount;
• discharging drilling fluid from said leading drill pipe section during the boring operation;
• removing the drill bit from the drill string at the surface exit location;
• attaching a reamer to the drill string at the exit location;
• pulling the drill string and reamer back through the pilot bore hole from the exit opening to the entrance opening in an opposite direction of travel while rotating said reamer with the reamer forming an enlarged opening;
• pushing the reamer back through the reamed hole from said entrance opening to said exit opening;
• connecting the production conduit to the reamer at said exit opening to permit rotation of the reamer relative to the production conduit;
• then pulling the reamer and production conduit back through the reamed opening from said exit opening to said entrance opening for installing the production conduit within the enlarged reamed hole;
• and
• rotating said drill string and reamer relative to the production conduit during pulling of the reamer and production conduit.

A method for drilling an arcuate underground pilot bore hole along a predetermined arcuate path in one direction of travel between two surface locations defining an entrance and an exit in a single drilling operation of a single constant diameter, and then enlarging the pilot bore hole in an opposite direction of travel between the surface locations to receive a production conduit therein, the bore hole being drilled by a drill pipe string of connected pipe sections having leading end sections formed of high strength non-magnetic material and having an outer diameter of at least around three inches, said drill pipe string including a leading drill pipe section, electrical survey equipment within the leading pipe section, and a drill bit on the end of the leading pipe section;

• said method comprising the steps of:
• providing thrusting means at the surface entrance location to advance the drill string and leading end section in one direction of travel along the arcuate path;
• providing means on said drill bit to permit a predetermined deviation of the leading pipe section upon a partial rotation of the leading pipe section a predetermined amount;
• circulating drilling fluid through said drill string during the drilling operation;
• removing the drill bit from the drill pipe string after exit from the exit location;
• attaching a reamer to the drill string at the exit location after the drill bit has been removed;
• pulling and simultaneously rotating the drill string and reamer along the pilot bore hole from the exit location to the entry location in an opposite direction of travel with the reamer forming an enlarged opening adapted to receive a production conduit;
• and
• circulating drilling fluid through said drill string during the reaming operation.

A method of drilling an arcuate underground pilot bore hole along a predetermined arcuate path in one direction of travel between two spaced surface locations in a single drilling operation of a single constant diameter, and then enlarging the pilot bore hole in an opposite direction of travel between the surface locations to receive a production conduit therein, the bore hole being drilled by a drill pipe string of connected pipe sections formed by high strength non-magnetic material, said drill pipe string including a leading drill pipe section, electrical survey equipment within the leading pipe section, a drill bit on the end of the leading pipe section, and an in-hole hydraulic motor having a longitudinal axis offset from the longitudinal axis of the drill pipe string for rotating the drill bit;

• said method comprising the steps of:
• advancing the leading drill pipe section carrying the drill bit and in-hole hydraulic motor along the arcuate path from a surface entry location to a surface exit location;
• providing a drive shaft between the drill bit and in-hole hydraulic motor for rotating the drill bit along the arcuate path between the two surface locations;
• providing a predetermined deviation of the leading pipe section upon a partial rotation of the leading drill pipe section and in-hole motor a predetermined amount;
• circulating drill fluid through the drill string to the hydraulic motor and drill bit for driving the hydraulic motor and providing drilling fluid for the drilling operation;
• removing the leading pipe sections with the drill bit and in-hole hydraulic motor from the drill string after exit from the surface exit location;
• attaching a reamer to the drill string at the exit location after removal of the leading pipe section;
• and
• pulling and simultaneously rotating the drill string and reamer along the pilot bore hole from the exit location to the entry location in an opposite direction of travel with the reamer forming an enlarged opening adapted to receive a production conduit.

A method of drilling an arcuate underground pilot bore hole along a predetermined path between two spaced surface locations utilizing a spud bit on a leading drill pipe section of a drill string with discharge nozzle means in a leading front face of the bit directly adjacent to the formation to be excavated and eroded;

• said method comprising the steps of:
• advancing the leading drill pipe section of the drill string having the spud bit thereon with said nozzle means in said front face positioned directly adjacent the formation to be excavated from a surface entrance location to a surface exit location;
• discharging drilling fluid from said nozzle means in a jet with the center of the drilling fluid jet being discharged offset from the longitudinal axis of the leading pipe section to aid in guiding the pipe string along the predetermined arcuate path;
• providing a predetermined partial rotation of the leading drill pipe section and the spud bit thereby to change the direction of offset of said nozzle means and the deviation of the leading pipe section.
• providing thrusting means at the surface entrance location to advance the drill string and spud bit thereon in a direction of travel along the arcuate path from an entrance opening to an exit opening;
• attaching a production conduit to the drill string at the exit location;
• and
• pulling the drill string and production conduit back through the bore hole from the exit opening to the entrance opening in an opposite direction of travel.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced earth surface locations;

• said apparatus comprising:
• a drill pipe string including a plurality of connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole;
• means at said one surface location to apply a thrust on said pipe string;
• said drill pipe string having a leading pipe section with a drill bit thereon and being of a flexibility greater than the other pipe sections;
• and,
• means to circulate drilling fluid during the drilling operation.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel, and then reaming an enlarged opening along the pilot bore hole in an opposite direction of travel while simultaneously placing a production conduit therein;

• said apparatus comprising:
• a drill pipe string including a plurality of threaded connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, said string including pipe sections of different strengths and a leading pipe section with a drill bit thereon;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface locations;
• means to circulate drilling fluid through said drill string during the drilling operation;
• a reamer connected to said drill string at the other surface location after the pilot bore hole is drilled between said spaced surface locations to form an enlarged opening along the pilot bore hole;
• a production conduit connected to said reamer and following said reamer through the enlarged opening formed by the reamer;
• said means at said one surface location including means for pulling said drill string, said reamer, and said production conduit along the enlarged opening in an opposite direction of travel, said pulling means at said one surface location rotating said drill string and reamer simultaneously with the pulling action;
• and
• said means to circulate drilling fluid providing drilling fluid for said reamer during the reaming operation.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced earth surface locations;

• said apparatus comprising:
• a drill pipe string including a plurality of connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole;
• means at said one surface location to apply a thrust on said pipe string;
• said drill pipe string having a leading pipe section with a drill bit thereon and being of a strength less than the pipe sections adjacent said means to apply a thrust;
• and
• means to circulate drilling fluid through said drill pipe during the drilling operation.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel, and then reaming an enlarged opening along the pilot bore hole in an opposite direction of travel while simultaneously placing a production conduit therein;

• said apparatus comprising:
• a drill pipe string including a plurality of threaded connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, said string including pipe sections of different strengths and a leading pipe section with a drill bit thereon;
• at least some of the leading pipe sections being of a reduced strength relative to at least some of the trailing pipe sections, and at least some of the leading pipe sections being of an increased flexibility relatively to at least some of the trailing pipe sections;
• means at said one surface locaton applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means to circulate drilling fluid through said drill string during the drilling operation;
• a reamer connected to said drill string at the other surface location after the pilot bore hole is drilled between said spaced surface locations to form an enlarged opening along the pilot bore hole;
• a production conduit connected to said reamer and following said reamer through the enlarged opening formed by the reamer;
• said means at said one surface location including means for pulling said drill string, said reamer, and said production conduit along the enlarged opening in an opposite direction of travel, said pulling means at said one surface location rotating said drill string and reamer simultaneously with the pulling action;
• and
• means operatively connecting the production conduit to the reamer;
• said means to circulate drilling fluid providing drilling fluid for said reamer during the reaming operation.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel, and then reaming an enlarged opening along the pilot bore hole in an opposite direction of travel while simultaneously placing a production conduit therein;

• said apparatus comprising:
• a drill pipe string including a plurality of threaded connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, said string including pipe sections of different strengths and a leading pipe section with a spud bit thereon;
• said spud bit having a planar forward end portion forming a flat front face thereof, said flat face having a discharge opening for receiving and discharging high velocity drilling fluid directly into the adjacent formation, and an intermediate planar portion slanting rearwardly from said front face for riding along the surface of the bore hole;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means to circulate drilling fluid through said drill string during the drilling operation;
• a reamer connected to said drill string at the other surface location after the pilot bore hole is drilled between said spaced surface locations to form an enlarged opening along the pilot bore hole;
• and
• a production conduit connected to said reamer and following said reamer through the enlarged opening formed by the reamer;
• said means at said one surface location including means for pulling said drill string, said reamer, and said production conduit along the enlarged opening in an opposite direction of travel, said pulling means at said one surface location rotating said drill string and reamer simultaneously with the pulling action;
• said means to circulate drilling fluid providing drilling fluid for said reamer during the reaming operation.

Apparatus for drilling a pilot bore hole along a predetermined underground arcuate path between two spaced surface locations comprising:

• a drill pipe string including a plurality of connected drill pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole and having a leading pipe section;
• means at said one surface location to apply an axial thrust to said pipe string;
• means to circulate drilling fluid through said drill pipe string during the drilling operation;
• and
• a spud bit on the leading pipe section of said pipe string having a leading end face thereon and fluid discharge nozzle means on said end face for discharging drilling fluid in a jet offset from the longitudinal axis of said leading pipe section to aid in guiding the pipe string along the predetermined arcuate path, said leading drill pipe section and said spud bit adapted to be partially rotated a predetermined amount to change the deviation of offset of said nozzle means and the deviation of the leading drill pipe section.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel, and then reaming an enlarged opening along the pilot bore hole in an opposite direction of travel for receiving a production conduit therein;

• said apparatus comprising:
• a drill pipe string including a plurality of connected threaded pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, the drill pipe string including a leading pipe section having a spud bit with a leading front face thereon;
• fluid discharge nozzle means on said front face for discharging drilling fluid in a jet having its center offset from the longitudinal axis of said leading pipe section to aid in guiding the pipe string along the predetermined arcuate path, said leading drill pipe section and said spud bit adapted to be partially rotated in a predetermined amount to change the directional offset of said nozzle means and the deviation of the leading drill pipe section;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means to circulate drilling fluid through said drill string during the drilling operation;
• a reamer connected to said drill string at the other surface location after the pilot bore hole is drilled between said spaced surface locations and after removal of the spud bit from the drill string;
• said means at said one surface location including means for pulling said drill string and said reamer along the pilot bore hole in the opposite direction of travel to form an enlarged opening for receiving a production conduit, said pulling means rotating said drill string and reamer simultaneously with the pulling action.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced earth surface locations;

• said apparatus comprising:
• a lightweight drill pipe string including a plurality of connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, each pipe section being of a high strength flexible non-ferrous alloy sufficient to permit a deflection of around five (5) degrees;
• means at said one surface location to apply an axial thrust to said pipe string;
• a spud bit on the leading pipe section of said drill pipe string having a leading front face thereon and forming said pilot bore hole of a single constant diameter, said front face having a discharge opening for receiving and discharging high velocity drilling fluid directly into the adjacent formation;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force the pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means associated with said spud bit for changing the deviation of the leading drill pipe section upon a partial rotation of said spud bit and leading drill pipe section a predetermined amount;
• means to circulate drilling fluid through said drill string during the drilling operation to provide drilling fluid through the fluid discharge opening in said spud bit;
• and
• a reamer connected to the drill string at the other surface location after the pilot bore hole of a single constant diameter is drilled between said spaced surface locations;
• said means at said one surface location including means for pulling said drill string and said reamer in an opposite direction of travel along the pilot bore hole from said exit opening to said entrance opening to enlarge the pilot bore hole for receiving a production conduit, said means to circulate drilling fluid providing drilling fluid for said reamer during the reaming operation.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined arcuate path between two spaced earth surface locations;

• said apparatus comprising:
• a lightweight drill pipe string including a plurality of connected drill pipe sections extending from one surface location into a bore entrance opening of the pilot bore, each drill pipe section being formed of a high strength aluminum alloy material and being of a flexibility to permit a deflection of around five (5) degrees;
• a separate high strength steel tool joint threaded onto each end of the aluminum drill pipe sections to form a male end on one end of the drill pipe section and a mating female end on the other end of the drill pipe section, the steel tool joints on adjacent aluminum drill pipe sections being threadedly connected to each other to form a high strength steel connection between adjacent aluminum drill pipe sections;
• a drilling bit on the leading end of the drill string for forming the pilot bore hole of a single constant diameter along the arcuate path from said bore entrance opening to a bore exit opening;
• a reamer connected to the drill string at the bore exit opening after the single diameter pilot bore hole is drilled between said spaced surface locations for enlarging the pilot bore hole;
• and
• means at said one surface location providing power for driving said drilling bit between said entrance opening and said exit opening, and for driving said reamer between said exit opening and said entrance opening to enlarge the pilot bore hole for receiving a production conduit.

Apparatus for boring an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel in a single boring operation of a single constant diameter, and then reaming an enlarged opening along the pilot bore hole in an opposite direction of travel for receiving a production conduit therein;

• said apparatus comprising:
• a lightweight drill pipe string including a plurality of threaded connected pipe sections having a diameter of at least around three (3) inches and extending from one surface location into a bore entrance opening of the pilot bore hole, said string being formed of a flexible high strength, non-ferrous material and including a leading pipe section having electrical survey equipment therein and a drill bit thereon;
• means associated with said bit for changing the deviation of the leading drill pipe section upon a partial rotation of the drill bit and leading pipe section a predetermined amount;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means to circulate drilling fluid through said drill string during the boring operation;
• a reamer connected to said drill string at the other surface location after the pilot bore hole is bored between said spaced locations to form an enlarged opening along the pilot bore hole;
• a production conduit at said other surface location adapted to be connected to said reamer and to follow said reamer through the enlarged opening formed by the reamer;
• said means at said one surface location including means for pulling said drill string, said reamer, and said production conduit along the enlarged opening in an opposite direction of travel, said pulling means at said one surface location rotating said drill string and reamer simultaneously with the pulling action;
• and
• said means to circulate drilling fluid providing drilling fluid for said reamer during the reaming operation.

Apparatus for boring an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel in a single boring operation of a single constant diameter, and then reaming an enlarged opening along the pilot bore hole in an opposite direction of travel for receiving a production conduit therein;

• said apparatus comprising:
• a lightweight drill pipe string including a plurality of threaded connected pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, at least the leading pipe section being formed of a high strength non-magnetic flexible alloy material to permit a deflection of at least around five (5) degrees and having a diameter of at least around three (3) inches, and electronic survey equipment within the leading pipe section;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• a reamer connected to said drill string at the other surface location after the pilot bore hole is bored between said spaced surface locations to form an enlarged opening along the pilot bore hole;
• a production conduit at said other surface location adapted to be connected to said reamer and to follow said reamer through the enlarged opening formed by the reamer;
• said means at said one surface location including means for pulling said drill string, said reamer, and said production conduit along the enlarged opening in an opposite direction of travel, said pulling means at said one surface location rotating said drill string and reamer simultaneously with the pulling action;
• and
• means to circulate drilling fluid through said drill string during the boring and reaming operations.

Apparatus for drilling an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaced surface locations in one direction of travel, and then pulling a production conduit along the bore hole in an opposite direction of travel;

• said apparatus comprising:
• a drill pipe string including a plurality of connected threaded pipe sections extending from one surface location into a bore entrance opening of the pilot bore hole, the drill pipe string including a leading pipe section having a spud bit with a leading front face thereon;
• fluid discharge nozzle means on said front face for discharging drilling fluid in a jet having its center offset from the longitudinal axis of said leading pipe section to aid in guiding the pipe string along the predetermined arcuate path, said leading drill pipe section and said spud bit adapted to be partially rotated in a predetermined amount to change the directional offset of said nozzle means and the deviation of the leading drill pipe section;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means to circulate drilling fluid through said drill string during the drilling operation;
• and
• a production conduit connected to said drill string at the other surface location after the pilot bore hole is drilled between said spaced surface locations and after removal of the spud bit from the drill string;
• said means at said one surface location including means for pulling said drill string and said production conduit through the bore hole in the opposite direction of travel.

Apparatus for boring an arcuate underground pilot bore hole along a predetermined inverted arcuate path between two spaved surface locations in one direction of travel in a single boring operation of a single constant diameter, and then pulling a production conduit along the bore hole in an opposite direction of travel;

• said apparatus comprising:
• a lightweight drill pipe string including a plurality of threaded connected pipe sections having a diameter of at least around three (3) inches and extending from one surface location into a bore entrance opening of the pilot bore hole, said string being formed of a flexible high strength, non-ferrous material and including a leading pipe section having electrical survey equipment therein and a drill bit thereon;
• means associated with said bit for changing the deviation of the leading drill pipe section upon a partial rotation of the drill bit and leading pipe section a predetermined amount;
• means at said one surface location applying a thrust on said pipe string in said one direction of travel to force said pipe string in a thrust action along the arcuate path in said one direction of travel to an exit opening at the other surface location;
• means to circulate drilling fluid through said drill string during the boring operation;
• and
• a production conduit at said other surface location connected to said drill string after removal of said drill bit;
• said means at said one surface location including means for pulling said drill string, and said production conduit along the bore hole in an opposite direction of travel.