DRILL RIG ANCHORING DEVICES, SYSTEMS, AND METHODS

Abstract

Devices, systems, and methods for anchoring a drill rig at a borehole are disclosed. An anchor assembly includes a rod mountable within a borehole, an adapter positioned on an end of the rod, an anchor face unit having a plurality of drill rig assembly mounting features, and an anchor clamp mounted to the anchor face unit. The anchor clamp has a plurality of jaws movable from an engagement position wherein said plurality of jaws are positioned within an adapter groove to a disengagement position wherein said plurality of jaws are positioned away from said adapter groove.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of the filing date of U.S. Provisional Patent Application No. 63/154,353, filed Feb. 26, 2021, which is incorporated herein by reference in its entirety.

FIELD

This application relates to devices, systems, and methods for anchoring drill rigs during drilling.

BACKGROUND

Some surface drill rigs, such as, for example, rotary drill rigs, have sufficient torque or axial force to render the drill rig unsteady during drilling. Underground drill rigs can likewise have sufficient torque or axial force to render the drill rig unstable. That is, the weight of the drill rig can be insufficient to keep the drill rig stable, particularly at low drilling angles (relative to a horizontal plane). The manufacturer, therefore, recommends operating the drill rig at a reduced capacity (e.g., less than 100% torque or axial force). This can limit drilling speed.

When drilling core holes, in an underground environment, the drill rig assembly needs to be secured/anchored to a rock wall that the hole is being drilled into. Due to the high axial forces required to drill a core hole, these forces create an opposite effect on the drill rig assembly causing it to move away, or towards, the rock wall. Depending on the angle of the core hole, these forces can push/pull the drill assembly in various ways. Since the drill rig assembly is not heavy enough to remain stationary while drilling the core hole, the drill rig assembly must be held in place with some type of “anchor system”.

One method of securing the drill assembly is through the use of an “anchor plate”. This anchor plate has slotted holes to allow a steel rod (rebar) to pass through these holes. A pneumatic drill (jackleg) is used to drill one-inch diameter holes approximately four to six feet deep. On smaller drill rig assemblies, two rebar are required to keep the drill rig assembly stationary. On larger drill rig assemblies, four rebar are used to hold the drill rig assembly stationary. The rebar rods are secured into the rock wall. Rebar plates are added to each side of the anchor plate on the drill rig assembly and secured with two nuts on each side of the anchor plate. As the drill rig assembly pushes and pulls axially, the forces that would cause the drill rig assembly to move are transferred to the rebar and rock wall allowing the drill rig assembly to remain stationary.

In another example, split-wedge anchors may be utilized in place of the rebar rods. In this example a core hole is formed in the drilling surface, to accept the split-wedge anchor assembly. Once the core hole is drilled, the drill rig assemblies' angle is changed, where the drilled core hole is aligned with an anchor point on the drill rig assembly. The split-wedge anchor assembly is a reusable system that can be used on multiple holes to secure the drill rig assembly. The split-wedge anchor is inserted into the drilled core hole and the threaded rod on the split-wedge anchor is placed through a slotted hole on the anchor frame. As the nut on the threaded rod on the split-wedge anchor is tightened, the wedge on the end of the split-wedge anchor assembly binds in the core hole. This binding action secures the split-wedge anchor to the drill rig and rock wall allowing the push and pull forces of the drill rig assembly to transfer to the split-wedge assembly and rock wall.

Therefore, surface drilling, underground drilling, and wall drilling could all benefit from a system that could anchor the drill rig during the drilling process. A secure method of anchoring the drill rig to the drill surface could allow operating the drill at full capacity. In addition, a secure method of anchoring the drill rig that can be installed both simply and reliably would improve both the installation process as well as the drilling process.

SUMMARY

Described herein, in various aspects, is a method for anchoring a drill rig. The method can comprise positioning an anchor at a borehole and coupling the drill rig to the anchor. Optionally, the drill rig can be used to drill at least one casing. The anchor can then be coupled to the at least one casing. It is contemplated that the disclosed anchoring systems and methods can be used in surface or underground drilling to improve drill rig stability.

In another aspect, the method can comprise drilling a borehole into a formation. An anchor mount is in installed into the borehole. An anchor face unit is mounted to a drill rig and is subsequently secured to the anchor face unit. This may include installing at least one casing within the borehole and coupling the anchor face unit to the casing.

The casing may include a plurality of casings and the coupling includes sassing each casing to the anchor face unit with a respective tie member. The tie members may include turnbuckles and by adjusting the operative length of the turnbuckles the anchor face unit is coupled to the casing. In another example the casing may include a central casing and the anchor face unit at least partially surrounds the central casing.

In another aspect, the anchor face unit may be welded to the central casing. The anchor face unit may include a main body having an underside defining a bolt hole pattern. A flange, including a plurality of threaded members that are receivable in the respective holes of the bolt hole pattern, may be coupled to the underside of the main body. A retainer ring may be welded to the central casing. In turn, the flange may be welded to the retainer ring. Afterwards, the weld between the retainer ring and the central casing may be cut.

In another aspect, the anchor face unit may include a main body and a retaining ring. The anchor face unit is mounted to the central casing by welding the retaining ring to the central casing.

In any aspect, the anchor face unit may comprise one or more fins extending from a central axis of the anchor face bottom surface. A ground anchor may be installed below a ground surface and the anchor face unit may be coupled to the ground anchor. The coupling may be achieved by coupling a tie rod to the anchor face unit with a nut such that the tie rod extends from the ground anchor to the anchor face unit.

In another aspect, the installation of the anchor mount to the borehole may comprise positioning a rod into the borehole, the rod having a first rod end inserted into the borehole and a second rod end extending from the borehole. An adapter is attached to the second rod end and includes an adapter groove.

Described herein, in various aspects, is also an anchor assembly for mounting a drill rig assembly to a formation within which a borehole has been formed. In one example the assembly includes a rod mountable within the borehole, the rod having a first rod end inserted into the borehole and a second rod end extending from the borehole. An adapted is positioned on the second rod end and defines an adapter groove. An anchor face unit is included and comprises a plurality of drill rig assembly mounting features. An anchor clamp is mounted to the anchor face unit and includes a plurality of jaws movable between a disengagement position, where the jaws are positioned away from the adapter groove, and an engagement position, where the jaws are positioned within the adapter groove.

The rod may comprise a hollow tubular rod with a threaded rod portion at the second rod end. The adapter may comprise a threaded adapter that removably engages the threaded rod portion. The first rod end may include a plurality of cutouts. A plurality of resin tubes may be positioned in the hollow tubular rod and a rod wiper may be positioned between the resin tubes and the second rod end. In this fashion, after the hollow tubular rod is positioned within the borehole, when pressure is applied to the second rod end, the rod wiper forces the plurality of resin tubes out through the plurality of cutouts and acts as a fixer between the hollow tubular rod and the borehole. The rod may include a plurality of circumferential grooves to fill with resin and further secure the hollow tubular rod within the borehole.

The anchor assembly may further include a plurality of actuators that are in communication with the plurality of jaws. These may include a wide variety of actuators including but not limited to hydraulic actuators. The anchor assembly may also include an actuator proximity switch and an actuator indicator light that operates to indicate when the plurality of jaws is in the engagement position.

In one aspect, the anchor assembly may also include a plurality of brake elements in communication with the plurality of jaws. The brake elements are movable between a brake locked position and a brake unlocked position. The brake elements prevent movement of the jaws in the brake locked position to prevent unwanted movement of the jaws from the engagement position. Although it is contemplated that this may be accomplished in a variety of fashions, in one example the brake elements may comprise a brake actuator wedge and a brake pad wedge. A spring element in communication with the brake actuator wedge biases into communication with the brake pad wedge to frictionally engage the actuator and prevent movement. When the spring bias is overcome with hydraulic or other intentional forces, the frictional engagement is released and the actuator is free to move. A brake proximity switch and a brake indicator light may be used in conjunction with the brake elements to provide a clear indication of when the brakes are in the brake locked position.

In another aspect, the anchor assembly may include clevis elements positioned between the brake elements and the actuators. The clevis elements may be positioned within receptor slots formed in the brake elements to provide secure engagement and positioning of the brake elements relative to the actuators.

In another aspect, the anchor assembly may be comprised of a clamp base plate, a pair of clamp side walls affixed to the clamp base plate and forming a slide channel, and a clamp cover plate. The plurality of jaws may be slidably retained within the slide channel. The actuators may be mounted to the clamp base plate and are configured to move the jaws within the slide channel between the disengagement position and the engagement position.

In one aspect, the anchor assembly may include a socket interface formed on the adapter. A socket adapter having a socket face may be configured to engage the socket interface and may include a threaded socket end configured to engage a drill rod tubular extension. This allows the rod to be inserted and secured into boreholes from extended distances as may be required where the formation having the borehole is remote or at an awkward angle.

In another aspect described herein, a method of anchoring a drill rig assembly to a wall of a formation is disclosed. The method includes drilling a borehole into the wall and positioning a rod within the borehole. A first rod end is inserted into the borehole and a second rod end extends from the borehole. An adapter is attached to the second rod end and the adapter defines an adapter groove. A drill rig assembly is mounted to an anchor face unit. An anchor clamp assembly is mounted to the anchor face unit. The anchor clamp assembly includes a plurality of jaws movable between an engagement position wherein the jaws are positioned within the adapter groove a disengagement position wherein the jaws are positioned away from the adapter groove. The anchor clamp assembly is placed around the anchor. The jaws are moved from the disengaged position to the engaged position and then locked.

In one aspect, the rod comprises a tubular rod and a plurality of resin filled tubes are inserted within the rod. A rod wiper is inserted into the rod and positioned between the resin filled tubes and the second rod end. The rod is inserted into the borehole and the second rod end is placed in communication with the drill rig assembly. The drill rig assembly rotates the rod while pressure is applied inside the rod. The pressure forces the resin fill tubes through a plurality of cutouts formed in the first rod end. The drill rig assembly continues to rotate the rod such that the resin is dispersed between the rod and the borehole.

In one aspect, a drill rod extension is mounted between the rod and the drill rig assembly to allow the rod to be installed in borehole located in a remote location.

In one aspect, a plurality of actuators are placed in communication with the plurality of jaws and are utilized to move the plurality of jaws between the disengaged position and the engaged position. In one particular aspect the plurality of actuators are attached to the hydraulic output of the drill rig assembly. This may include attaching a hydraulic valve bank and a hydraulic oil tank. An actuator flow lever may be utilized to control flow of hydraulic fluid to the actuators such they move the jaws from the disengaged position to the engaged position.

Similarly, in one aspect, a plurality of brake elements are attached to the plurality of actuators and are utilized to prevent movement of the jaw elements out of the engaged position when activated. In one particular aspect, the bake elements are movable between a brake unlocked position and a brake locked position. The brake elements may be biased towards the brake locked position and moved to the brake unlocked position by way of the application of hydraulic pressure. The brake elements may be attached to the drill rig hydraulic output using a doubled sectioned hydraulic valve bank and operated by way of a brake flow lever. The brake elements may include a brake position sensor and a brake indication light to provide a visual confirmation when the brake elements are in the brake locked position.

In one aspect, wherein the drill rig assembly is to be mounted in a remote location, the adapted may include a socket face formed therein opposite the threaded adapter portion. A socket adapter having a socket face may be placed in communication with the adapter and rotated by the drill rig assembly such that the threaded adapter portion engages the threaded rod portion. In this aspect, a drill rod extension may be positioned in between the socket adapter and the drill rig assembly to allow to adapter and rod to be installed in a remote located bore hole.

Additional advantages of the disclosed apparatuses, systems, and methods will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the disclosed apparatuses, systems, and methods will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

DESCRIPTION OF THE DRAWINGS

These and other features of the preferred embodiments of the disclosed apparatuses, systems, and methods will become more apparent in the detailed description in which reference is made to the appended drawings wherein:

FIG. 1 is a perspective view of a drill rig with a main body of an anchor coupled thereto in accordance with embodiments disclosed herein.

FIG. 2 is a perspective view of the drill rig and main body of the anchor of FIG. 1 positioned between casings for coupling to the anchor.

FIG. 3A is a perspective view of the anchor coupled to the casings of FIG. 2.

FIG. 3B is a detail of the anchor coupled to the casings of FIG. 3A.

FIG. 4 shows three perspective views of an exemplary anchor in accordance with embodiments disclosed herein.

FIG. 5A shows a perspective view of the anchor of FIG. 4 coupled to the drill rig and a detailed view of a portion of the anchor and drill rig.

FIG. 5B is a detail of a portion of the anchor shown in FIG. 5A.

FIG. 6 shows a perspective view of an exemplary anchor in accordance with embodiments disclosed herein and a partial cross sectional view thereof with a tie rod for coupling the anchor to a ground anchor.

FIG. 7A shows a perspective view of the exemplary anchor of FIG. 6 with the drill rig.

FIG. 7B shows a close-up detail view of the exemplary anchor shown in FIG. 7A.

FIG. 8 is a perspective view of an exemplary anchor in accordance with embodiments disclosed herein.

FIG. 9 is a perspective view of the anchor of FIG. 8 and a drill rig coupled thereto.

FIG. 10 is a perspective view of the anchor and drill rig of FIG. 9 with a casing pipe coupled thereto.

FIG. 11 is a perspective view of the anchor in multiple separated components for removal.

FIG. 12 is a perspective view of an exemplary anchor in accordance with embodiments disclosed herein with a drill rig coupled thereto.

FIG. 13 is a top view of a component of a retainer ring as disclosed herein.

FIG. 14 is a perspective view of a shear pin for coupling the drill rig to the anchor as in FIG. 9.

FIG. 15 is a perspective view of an exemplary anchor assembly for mounting a drill rig assembly as disclosed herein.

FIG. 16 is a detailed view of the anchor assembly shown in FIG. 15.

FIG. 17A is a cross-sectional perspective view of the formation, borehole and rod hidden in FIGS. 15-16.

FIG. 17B is a perspective view of the formation, borehole and rod in FIG. 17A.

FIG. 18 is a side view of the rod utilized in FIGS. 15-17.

FIG. 19 is a perspective view of the rod shown in FIG. 18.

FIG. 20 is a perspective view of an exemplary rod, resin filled tubes, and rod wiper.

FIG. 21 is a detail of the rod shown in FIG. 20, the detail showing the first rod end.

FIG. 22 is a cross-section view of an exemplary rod inserted in the borehole, with the rod wiper positioned in the resin storage position as disclosed herein.

FIG. 23 is a cross-section view of an exemplary rod inserted in the borehole, with the rod wiper positioned in the resin dispersal position as disclosed herein.

FIG. 24 is a perspective view of an adapter for use with the anchor assembly shown in FIG. 15.

FIG. 25 is a side view of the adapter shown in FIG. 24.

FIG. 26 is a front view of the adapter shown in FIG. 24.

FIG. 27 is a perspective view of a socket adapter for use in the anchor assembly shown in FIG. 15.

FIG. 28 is a side view of the socket adapter shown in FIG. 27.

FIG. 29 is a perspective view of the adapter and socket adapter of FIGS. 24-28.

FIG. 30 is a cross-sectional view of an exemplary anchor assembly as disclosed herein:

FIG. 31 is a detailed cross-sectional view of the anchor assembly shown in FIG. 30.

FIG. 32 is an exploded perspective view of an exemplary anchor clamp of the anchor assembly as shown in FIGS. 30-31.

FIG. 33 is a perspective view of an exemplary anchor clamp and anchor face unit for use in the anchor assembly shown in FIG. 15.

FIG. 34 is a cross-sectional view of a rod inserted in a borehole, showing the jaws of an exemplary anchor assembly in the engaged position as disclosed herein.

FIG. 35 is a cross-sectional view of a rod inserted in a borehole, showing the jaws of an exemplary anchor assembly in the disengaged position as disclosed herein.

FIG. 36 is a cross-sectional view of a brake element, with the brake element shown in the braked locked position as disclosed herein.

FIG. 37 is a cross-sectional view of the brake element of FIG. 36, with the brake element shown in the braked unlocked position as disclosed herein.

FIG. 38 is a perspective view of an exemplary anchor clamp mounted to an exemplary anchor face unit as disclosed herein.

FIG. 39 depicts an exemplary hydraulic output of a drill rig assembly in communication with actuators and brake actuators as disclosed herein.

FIG. 40 depicts an exemplary hydraulic valve bank for use with the anchor assembly shown in FIG. 15.

FIG. 41 is an illustration of an exemplary hydraulic actuation of the actuators and brake actuators disclosed herein. As shown, the hydraulic actuation can be accomplished using a hydraulic oil tank.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. It is to be understood that this invention is not limited to the particular methodology and protocols described, as such may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present invention.

Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

As used herein the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, use of the term “a fin” can refer to one or more of such fins, and so forth.

All technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs unless clearly indicated otherwise.

As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

As used herein, the term “at least one of” is intended to be synonymous with “one or more of.” For example, “at least one of A, B and C” explicitly includes only A, only B, only C, and combinations of each.

Ranges can be expressed herein as from “approximately” one particular value, and/or to “approximately” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “approximately,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. Optionally, in some aspects, when values are approximated by use of the antecedent “approximately,” it is contemplated that values within up to 15%, up to 10%, up to 5%, or up to 1% (above or below) of the particularly stated value can be included within the scope of those aspects.

As used herein, when referring to elements outside a formation or borehole, the term “downwardly” can refer to a direction oriented toward the formation or borehole, even if such direction has a horizontal component. Similarly, as used herein, the term “upwardly” can refer to a direction away from a formation or borehole, even if such direction has a horizontal component.

The word “or” as used herein means any one member of a particular list and, except where otherwise indicated, can also include any combination of members of that list.

It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow: plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus, system, and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the apparatus, system, and associated methods can be placed into practice by modifying the illustrated apparatus, system, and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry.

Disclosed herein, in various aspects, is an anchoring system and method for anchoring a drill rig assembly to a formation. A formation is intended to encompass any surface that is intended to be drilled. Exemplary formations can comprise rock, sand, and/or soil. Such formations can be soft formations (e.g., formations comprising clays, red beds, shale, soft limestone, unconsolidated sand, and the like), medium formations (e.g., formations comprising calcites, dolomites, hard shale, hard limestone, and the like), and/or hard formations (e.g., formations comprising calcites, cherty limestone, hard shale, mudstones, and the like). A bore hole is drilled into the formation for receipt of an anchoring attachment. The anchoring attachment is secured within the borehole. An anchor face unit is attached to the drill rig assembly. The anchor face unit is adapted to be secured to the anchoring attachment such that the drill rig assembly may be secured to the formation and the drill rig assembly may be operated without the drill rig assembly wandering or misaligning during the drilling process. The formation can be underground or above ground. The disclosed anchoring system can be utilized in a wide variety of drilling applications.

Disclosed herein, with reference to FIGS. 1-3A/3B, is an anchoring system and method for anchoring a drill rig assembly 10 having a mast 12 in according to a first exemplary aspect. The anchor system can comprise an anchor face unit 102. The anchor face unit 102 can comprise a main body 104 that can be coupled to the drill rig assembly 10 with the mast 12 in a lowered position (FIG. 2). For example, a crane can position the main body 104 of the anchor face unit 102 on the mast, and the anchor face unit 102 can be bolted or otherwise coupled to the drill rig. In further aspects, the anchor face unit 102 can couple to the drill rig using shear pins, as further disclosed herein. The drill rig assembly 10 can then be positioned at the drilling site (e.g., positioned over a well center 14). The main body 104 of the anchor can be configured to partially or entirely encircle the well center 14. The main body 104 can define a sufficient inner radius to encircle a maximum size casing (e.g., at least 40 inches, or 42 inches).

One or more casings 110, or casing pipe, can be inserted into the ground around, and spaced laterally from, the well center. In some aspects, a sonic drill rig (optionally, a second drill rig) can be used to install such casings. In further aspects, the drill rig assembly 10 can be used to drill a borehole for such casings 110. It is contemplated that the drill rig assembly 10 can be operated at a reduced capacity while drilling pilot holes for the casings. The casings 110 can optionally be inserted to a depth of 50 feet or until refusal. In an exemplary aspect, four casings 110 (e.g., four six-inch casings) can be inserted. The casing 110 can optionally be spaced by about twenty feet in a first horizontal dimension 30 and twenty-two feet in a second horizontal dimension 32. The dimensions disclosed herein and shown in the Figures should be understood to be optional, and other dimensions are contemplated.

A pair of torque arms 106 can be coupled to the main body 104 of the anchor face unit 102 on each side. Each of the torque arms 106 can extend along the second horizontal dimension 32.

A coupling member 120 can couple each casing pipe to the torque arm 106 on the same side of the drill rig assembly 10. In some aspects, the coupling member can comprise a turnbuckle 122 that can be used to adjust the length of the coupling member so that the coupling member can be retained in tension (e.g., 20,000 lbf of pre-load). In further aspects, a ratchet binder can be used instead of, or in addition to, the turnbuckle 122. The coupling member 120 can further comprise a cable 124. In still further aspects, the coupling member 120 can comprise a ring 126 that can encircle the casing 110.

Using the anchor as disclosed herein, torque from the drill rig can be transferred via the coupling member 120 to the casings 110 to thereby inhibit rotation of the drill rig assembly 10 about the drilling axis.

Referring to FIGS. 4-5A/B, according to a second aspect, an anchor 200 can have a central axis 202 and a bottom surface 204. One or more fins 206 can extend downwardly from the bottom surface 204. In some optimal aspects, the fins 206 can each have a major dimension that extends outwardly from the central axis. For example, the fins 206 can optionally extend parallel to a respective ray 208 that extends perpendicularly to the central axis 202 and through the respective fin 206. In further aspects, the fins 206 can define an acute angle relative to the respective ray 208. The fins can comprise one or more struts 210 that extend transversely to the major dimension of the respective fin 206. When the anchor 200 is placed on the ground, the fins 206 can sink into the ground to inhibit rotation of the anchor 200. For harder ground, trenches can be dug to receive each of the fins 206.

Referring also to FIG. 5B, the anchor 200 can comprise an upwardly extending bracket 212 that defines respective slots 214 that receive shear pins 22 of the drill rig assembly 10. In this way, the drill rig can couple to, and transfer torque to, the anchor 200. Optionally, mounting brackets can be coupled to the end of the drill rig assembly 10 on each side (spaced along the second horizontal dimension 32), and the shear pins 22 can extend through, and be coupled to, respective mounting brackets.

Referring also to FIGS. 6, 7A, and 7B, a ground anchor can be positioned below the ground surface (e.g., using an excavator or backhoe). A coupling member can extend between, and couple to, the ground anchor and the anchor 200. For example, in some optional aspects, the anchor 200 can comprise a base surface 220 that defines at least one (e.g., two, as shown) through holes 228. A respective tie rod 230 can couple to the ground anchor and can extend through a respective hole 228, and a nut 232 can be tightened down against the base surface to retain the tie rod 230.

Referring to FIGS. 8-12, according to a third aspect, an anchor 300 can be welded to a central casing 302. The central casing 302 can be positioned in the formation. Optionally, the drill rig assembly 10 can, before being anchored, drill and install the central casing 302, optionally, while operating at a reduced capacity (e.g., lower torque and/or axial loading). For example, optionally, the drill rig can drill a 30-inch pilot hole to a depth of 60 feet, and a 26-inch×½ inch wall casing string can be inserted into the pilot hole. Optionally, the casing string can comprise radial ribs welded to the casing outside diameter in order to inhibit rotation of the casing string within the pilot hole.

The anchor 300 can comprise a main body 304 defining a plurality of holes 306 arranged in a bolt hole pattern. The main body 304 of the anchor 300 can have an underside 308 defined by a plate 309. A flange 310 can comprise a plurality of upwardly extending threaded members 312 that are receivable into respective holes 306 of the bolt hole pattern. The flange 310 can be positioned beneath, and coupled to, the underside 308 of the main body 304 of the anchor 300. A plurality of nuts (not shown) can threadedly engage the threaded members 312 of the flange 310.

A retainer ring 314 can be positioned over and around the casing so that the retainer ring 314 rests against an upper side 316 of the flange 310. The retainer ring 314 can be welded to the flange 310 and the casing 302. It is contemplated that the flange 310 can define a larger inner diameter than the retainer ring 314. Before welding, the retainer ring 314 can move transversely to the central axis of the flange 310 to accommodate misalignment between the drill rig assembly 10/main body 304 and the central casing 302.

Referring also to FIG. 13, optionally, the retainer ring 314 can comprise two separable components 330. The separable components 330 can have rotational symmetry so that one separable component 330 can couple to an identical separable component 330 via interlocking features 332a, b to form the retainer ring 314. In this way, the retainer ring can easily be placed around the casing, rather than requiring that it be lifted over the casing. Still further, the retainer ring 314 can enable the anchor 300 to be adapted to different size/diameter casings. For example, the inner diameter (or inner dimensions) of the retainer ring 314 can be selected to be the same as, or substantially the same as, the outer diameter of the casing, and the outer diameter of the retainer ring 314 can be a suitable diameter to couple to the rest of the anchor 300. Accordingly, in some aspects, a kit can comprise a plurality of retainer rings 314 having different inner diameters (or suitable inner dimensions) for adapting the anchor 300 to different casing sizes.

The anchor 300 can comprise an upwardly extending bracket 313 that defines respective slots 315 with open top ends that the receive shear pins 22 of the drill rig assembly 10. An exemplary shear pin is shown in FIG. 14. It is contemplated that the slots 315 can permit misalignment between the rig mast and the well centerline 14. The casing ends can be out of square, requiring alignment to the downhole casing before welding. The two opposing pins 22 can transmit torque and feed forces to the anchor frame. During near-horizontal drilling in which the rig may move under feed forces, the open-ended slots 315 can be closed (e.g., a member can extend across the top opening of the slots 315) to withstand both torque and axial feed force.

Optionally, the main body 304 can define pockets 340 (e.g., within a ring-shaped guide) that can receive respective rig jacks 18 (FIG. 7) of the trailer frame of the drill rig assembly 10. These feet can provide a guide for aligning the drill rig assembly to the anchor during setup activities prior to commencing drilling. The weight of the drill rig assembly 10 can be transferred through the rig jacks 18, through the anchor 300, and to the casing 302. It is contemplated that this configuration can advantageously provide additional support to the rig when on soft ground. The anchor can comprise stiffening members extending across the upper surface to the plate 309 to provide rigidity to the plane 309 for supporting the weight of the rig.

Referring to FIG. 11, once the drilling is complete, the main body 304 of the anchor 300 can be lifted from the flange, and the welds between the retainer ring 314 and the flange 310, and between the retainer ring 314 and the central casing 302, can be cut or otherwise removed.

In further aspects, as shown in FIG. 12, an anchor 300′ can comprise a main body 304′ and a retaining ring 314′, and the retaining ring 314′ can be welded or otherwise coupled directly to the main body 304′ and the central casing 302.

Disclosed herein, with reference to FIGS. 15-17A/B, is an anchor assembly 400 for mounting a drill rig assembly 402 to a wall 404 of a formation 406 within which a borehole 408 is formed. Although a wall 404 and formation 406 are disclosed, the present disclosure is applicable to a wide range of surfaces and drilling scenarios including, but not limited to, above ground (surface) drilling and below ground (underground) drilling. The disclosure includes an anchor mount such as at least one rod 410 that is mountable within the borehole 408. The rod 410 may include a range of elongated shapes and in one example comprises a hollow structure. In one example, the rod 410 comprises a tubular cylindrical rod. The rod 410 has a first rod end 412 that is inserted in the borehole 408 and a second rod end 414 that extends from the borehole 408 once the rod 410 has been mounted therein.

In one example, referring to FIGS. 18-21, the rod 410 may include a threaded rod portion 416 at the second rod end 414. The rod 410 may include an open end 418 at the first rod end 412 that includes a plurality of cutouts 420 formed therein. In one example, the plurality of cutouts 420 may comprise v-shaped cutouts. The rod 410 may further include a plurality of circumferential grooves 422 formed around the tubular rod outer surface 424. The rod 410 may form a hollow rod internal region 426. In one example, a plurality of resin filled tubes 428 are positioned within the hollow rod internal region 426. A rod wiper 430 is positioned within the hollow rod internal region 426 between the plurality of resin filled tubes 428 and the second rod end 414.

The first rod end 412 may be placed in communication with the drill rig assembly 402 (see FIG. 22) and the first rod end 412 is inserted into the borehole 408. The drill rig assembly 402 is utilized to rotated the rod 410 within the borehole 408. A pressure 432 is applied to the hollow rod internal region 426 of the rod 410 which forces the rod wiper 430 from a resin storage position 434 to a resin dispersal position 436 (see FIG. 23), As the rod wiper 430 moves from the resin storage position 434 to the resin dispersal position 436, the plurality of resin filled tubes 428 are forced through the plurality of cutouts 420 and the resin 438 contained therein is dispersed between the rod 410 and the borehole 408. The rotation of the rod 410 by the drill rig assembly 402 allows the resin 438 to be dispersed in the area between the rod 410 and the borehole 408. The plurality of circumferential grooves 422 formed on the tubular rod outer surface 424 further provides the resin 438 forming a secure bond between the rod 410 and the borehole 408 as the resin 438 cures. It is contemplated that the pressure 432 may be applied to the hollow rod internal region 426 in a variety of fashions. In one aspect of the disclosure, the pressure 432 comprises water pressure introduced into the rod 410. In another, the pressure 432 may comprise hydraulic pressure provided by the drill rig assembly 402. In still another, air pressure may be utilized to provide the pressure 432 inside the rod 410.

Referring now to FIGS. 24-26, the anchor assembly 400 may further include an adapter 440 configured to attach to the second rod end 414 of the rod 410. In one aspect, the adapter 440 includes a threaded adapter portion 442 configured to engage the threaded rod portion 416 located at the second rod end 414. The adapter 440 may include an adapter groove 444 formed therein. The adapter 440 may further include a socket interface 446 opposite the threaded adapter portion 442. The socket interface 446 is configured to engage a socket adapter 448 having a socket face 450 and a threaded socket end 452 (see FIGS. 27-29). The threaded socket end 452 is configured to engage a drill rod tubular extension 454 that may be mounted to the drill rig assembly 402 (see FIGS. 30-31). Utilization of the drill rod tubular extension 454 along with the socket adapter 448 allows the adapter 440 to be installed in remote locations such as high or awkward formation 406 placements without requiring close proximity to the drilling rig assembly 402.

The anchor assembly 400 may further include an anchor clamp 456 configured to engage the adapter groove 444 of the adapter 440 (see FIGS. 30-33). The anchor clamp 456 may include a plurality of jaws 458 that are movable between an engagement position 460 (see also FIG. 34) and a disengagement position 462 (see also FIG. 35). In the engagement position 460, the plurality of jaws 458 are positioned within the adapter groove 444 and in the disengagement position 462 the plurality of jaws 458 are positioned away from the adapter groove 444. While in the engagement position 460, the anchor clamp 456 is locked to the adapter groove 444 and subsequently the rod 410 and is therefore anchored to the formation 406 upon which the rod 410 is secured.

In one aspect, the anchor clamp 456 may be comprised of a clamp base plate 464 and a pair of clamp side walls 466 affixed thereto to form a slide channel 468. The anchor clamp 456 further comprises a clamp cover plate 470 affixed to the pair of claim side walls 466 and covering the slide channel 468. The plurality of jaws 458 are housed and movable within the slide channel 468. A plurality of shim plates 472 may be positioned between clamp base plate 464, the clamp side walls 466, the plurality of jaws 458 and the clamp cover plate 470 to facilitate free movement of the plurality of jaws 458 within the slide channel 468.

In at least one example, the plurality of jaws 458 are in communication with a plurality of actuators 474. The plurality of actuators 474 are configured to move the plurality of jaws 458 between the engagement position 460 and the disengagement position 462. In one aspect, the plurality of actuators 474 are contemplated to comprise hydraulic actuators. In still another, the plurality of actuators 474 are contemplated to comprise hydraulic cylinder actuators comprising a hydraulic pressure element 476 and a cylinder driver 478. The cylinder drivers 478 are in communication with the plurality of jaws 458 and slide the jaws 458 within the slide channel 468. In one aspect, the cylinder drivers 478 are attached to a plurality of clevis elements 480. The plurality of clevis elements 480 may be positioned in a plurality of receptor slots 482 each formed in one of the plurality of jaws 458. (see FIG. 33). It should be understood that the left clevis element 480 shown in FIG. 33 is illustrated outside the receptor slot 482 for illustrative purposes only and is not intended to demonstrate operational status. In one example, the plurality of actuators 474 may include an actuator proximity switch 484 and an actuator indicator light 486. This may allow operators to verify the status of the actuator 474 position visually.

The anchor clamp 456 may further include a plurality of brake elements 488 in communication with the plurality of actuators 474 (see FIGS. 33, 36-37). The plurality of brake elements 488 are movable between a brake locked position 490 (FIG. 36) and a brake unlocked position 492 (FIG. 37). The brake elements 488 prevent movement of the plurality of jaws 458 when in the brake locked position 490. This allows the plurality of jaws 458 to be secured in the engagement position 460 and remaining within the adapter groove 444. Although a variety of brake elements 488 are contemplate, in one example the brake elements 488 may comprise brake actuator wedge 494 positioned within a brake element housing 496. The brake actuator wedge 494 is biased by way of a spring element 498 in communication with the brake actuator wedge 494 towards the brake locked position 490. In the brake locked position 490, the brake actuator wedge 494 is forced into frictional contact with a brake pad wedge 500. This, in turn, forces the brake actuator wedge 494 into frictional contact with the actuator 474. In this particular aspect, the brake pad wedge 500 is forced into contact with the cylinder driver 478 of the actuator 474.

When it is desirable to move the brake elements 488 into the brake unlocked position 492, a brake actuator 502 may be applied to the brake actuator wedge 494 to move away from the brake pad wedge 500 and the cylinder driver 478 is free to move. Although a variety of brake actuators 502 may be utilized, in one aspect a hydraulic brake actuator 502 is contemplated. The hydraulic brake actuator 502 applies hydraulic forces against the brake actuator wedge 494 to overcome the biasing forces of the spring element 498. A brake proximity switch 504 and a brake indicator light 506 may be utilized to provide the operator visual confirmation the brake element 488 is in the brake locked position 490.

The anchor clamp 456 may be mounted to an anchor face unit 508 to facilitate its mounting to the drill rig assembly 402 (see FIG. 38 as well as FIGS. 30, 31 and 33). The anchor face unit 508 includes a plurality of drill rig assembly mounting features 510 to allow the anchor face unit 508 to be securely attached to the drill rig assembly 402. In at least one aspect the anchor clamp 456 is bolted to the anchor face unit 508 and the anchor face unit 508 is bolted to the drill rig assembly 402. In other aspects, not shown, it is contemplated that the anchor clamp 456 may be mounted directly to the drill rig assembly 402.

Referring now to FIGS. 39-41, in the aspects disclosed herein utilizing hydraulic actuation, the plurality of actuators 474 as well as the plurality of brake actuators 502 may be placed in communication with a hydraulic output 512 of the drill rig assembly 402. A hydraulic valve bank 514 may be utilized to control the flow of hydraulic fluid to the actuators 474 and/or the brake actuators 502. Where both the actuators 474 and the brake actuators 502 are controlled hydraulically, the hydraulic valve bank may comprise a double sectioned hydraulic valve bank as depicted in FIG. 40. The hydraulic valve bank 514 may include an actuator flow lever 516 and/or a brake flow lever 518. The actuator flow lever 516 when activated allows hydraulic fluid from the hydraulic output 512 to flow to the plurality of actuators 474 moving controlling their movement of the plurality of jaws 458 between the disengagement position 462 and the engagement position 460. The brake flow lever 518 when activated allows hydraulic fluid from the hydraulic output 512 to flow to the brake actuators 502 which move the brake elements 488 moving them from the brake unlocked position 492 to the brake locked position 490. In one contemplated aspect, when the flow levers 516, 518 are released, the hydraulic fluid contained in the actuators 474, 502 is released to flow into a hydraulic oil tank 520.—When the brake flow lever 518 is activated, it sends hydraulic oil to the brake assembly 502 and releases the brake from the cylinder driver 478. When hydraulic oil and hydraulic pressure is removed from the brake assembly, the springs inside the break assembly lock the cylinder driver into its current position.

The present application, in at least one aspect discloses a method of anchoring a drill rig assembly 400 to a formation 406 that comprises drilling a borehole 408 into the formation 406 and installing at least one anchor mount (such as a casing 110 or a rod 410) into the borehole 408. The method may include mounting a drill rig assembly 10, 402 to an anchor face unit 102, 508. The method may also include securing the anchor face unit 102, 508 to the anchor mount 110, 410. The method may include the casing 110 comprising a central casing and the anchor face unit 102 is positioned such that it at least partially surround the central casing 110.

In one aspect, the installing of the anchor mount may comprise installing at least one casing 110 within the borehole 408 and securing the anchor face unit 102 may comprise coupling the anchor face unit 102 to the casing 110. The casing 110 may comprise a plurality of casings and coupling the anchor face unit 102 to the casing 110 may comprise coupling each sassing of the plurality of casings 110 to said anchor face unit 102 with a respective tie member 230. The coupling may comprise adjusting an operative length of a turnbuckle 122 of the tie member 230.

It should be understood that combinations of the various aspects of each of the different embodiments disclosed herein are also contemplated.

Exemplary Aspects

In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not however be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

Aspect 1. An anchor assembly for mounting a drill rig assembly to a wall of a formation within which a borehole is formed, the anchor assembly including a rod mountable within the borehole, the rod including a first rod end inserted into the borehole and a second rod end extending from the borehole. The assembly further including an adapter positioned on the second rod end, the adapter defining an adapter groove. The assembly includes an anchor face unit comprising a plurality of drill rig assembly mounting features. The assembly includes an anchor clamp mounted to the anchor face unit, the anchor clamp comprising a plurality of jaws movable from an engagement position wherein the plurality of jaws are positioned within the adapter groove to a disengagement position wherein the plurality of jaws are positioned away from the adapter groove.

Aspect 2. The anchor assembly of aspect 1, wherein the rod comprises a hollow rod.

Aspect 3. The anchor assembly of aspect 1 or aspect 2, wherein the rod comprises a tubular rod.

Aspect 4. The anchor assembly of any one of the preceding aspects, wherein the rod comprises a threaded rod portion at the second rod end; and wherein the adapter comprises a threaded adapter portion, the threaded adapter portion removably engaging the threaded rod portion.

Aspect 5. The anchor assembly of any one of the preceding aspects, wherein the first rod end comprises an open end having a plurality of cutouts.

Aspect 6. The anchor assembly of any one of the preceding aspects, wherein the assembly further includes a plurality of resin filled tubes positioned within the rod and a rod wiper positioned within the rod in between the plurality of resin filled tubes and the second rod end, the rod wiper movable between a resin storage positon and a resin dispersal position, the rod wiper when in the resin dispersal position forcing the plurality of resin filled tubes through the plurality of cutouts to disperse a resin between the rod and the borehole.

Aspect 7. The anchor assembly of Aspect 6, wherein the rod comprises a plurality of rod circumferential grooves formed on a tubular rod outer surface.

Aspect 8. The anchor assembly of Aspect 5, wherein the plurality of cutouts comprise a plurality of V-shaped cutouts.

Aspect 9. The anchor assembly of any one of the preceding aspects, wherein the assembly includes a plurality of actuators in communication with the plurality of jaws, the plurality of actuators configured to move the plurality of jaw between the engagement position and the disengagement position.

Aspect 10. The anchor assembly of Aspect 9, wherein the assembly includes an actuator proximity switch and an actuator indicator light, wherein the actuator indicator light operates to identify one of the plurality of jaws are in the engagement position.

Aspect 11. The anchor assembly of Aspect 9, wherein the plurality of actuators comprise a plurality of hydraulic actuators.

Aspect 12. The anchor assembly of Aspect 9, wherein the plurality of actuators comprises a plurality of hydraulic cylinder actuators.

Aspect 13. The anchor assembly of Aspect 9, wherein the assembly includes a plurality of brake elements in communication with the plurality of jaws, the plurality of brake elements movable between a brake locked position and a brake unlocked position, the plurality of brake elements preventing movement of the plurality of jaws in said brake locked position.

Aspect 14. The anchor assembly of Aspect 13, wherein each of the plurality of brake elements includes a brake actuator wedge, a spring element in communication with the brake actuator wedge, and a brake pad wedge in communication with the brake actuator wedge and one of the plurality of actuators, wherein the spring element biases the brake actuator wedge into the brake pad wedge to frictionally engage one of the plurality of actuators.

Aspect 15. The anchor assembly of Aspect 14, wherein the brake actuator edge is in communication with a brake actuator, the brake actuator countering the bias of the spring element to move the brake actuator wedge away from the brake pad wedge to remove frictional engagement of the brake pad wedge from one of the plurality of actuators.

Aspect 16. The anchor assembly of Aspect 13, wherein the plurality of brake elements are biased towards the brake locked position using a spring bias.

Aspect 17. The anchor assembly of Aspect 13, wherein the plurality of brake elements are moved from the brake locked position to the brake unlocked position by a brake actuator.

Aspect 18. The anchor assembly of Aspect 13, wherein the assembly includes a brake proximity switch and a brake indicator light, wherein the brake indicator light operates to identify the brake is in the brake locked position.

Aspect 19. The anchor assembly of Aspect 13, wherein plurality of brake elements are moved from the brake locked position to the brake unlocked position by a hydraulic brake actuator.

Aspect 20. The anchor assembly of Aspect 9, wherein the assembly includes a plurality of clevis elements each of which is attached to one of the plurality of actuators, wherein each of the plurality of clevis elements is in communication with one of the plurality of jaws.

Aspect 21. The anchor assembly of Aspect 20, wherein the assembly includes a plurality of clevis elements each of which is attached to one of the plurality of actuators, wherein each of the plurality of clevis elements is in communication with one of the plurality of jaws.

Aspect 22. The anchor assembly of any one of the preceding aspects, wherein anchor clamp includes a clamp base plate, a pair of clamp side walls affixed to the clamp base plate and forming a slide channel, and a clamp cover plate affixed to the pair of claim side walls and covering the slide channel, wherein the plurality of jaws are slidably retained within the slide channel.

Aspect 23. The anchor assembly of Aspect 22, wherein the assembly includes a plurality of actuators mounted to the clamp base plate and in communication with the plurality of jaws, the plurality of actuators configured to slide the plurality of jaws inside the slide channel between the engagement position and the disengagement position.

Aspect 24. The anchor assembly of Aspect 23, wherein the plurality of actuators comprises a plurality of hydraulic actuators.

Aspect 25. The anchor assembly of Aspect 23, wherein the plurality of actuators comprises a plurality of hydraulic cylinder actuators.

Aspect 26. The anchor assembly of Aspect 4, wherein the adapter further comprises a socket interface opposite the threaded adapter portion.

Aspect 27. The anchor assembly of Aspect 26, wherein the assembly includes a socket adapter having a socket face configured to engage the socket interface and a threaded socket end configured to engage a drill rod tubular extension.

Aspect 28: A method of anchoring a drill rig assembly to a wall of a formation comprising: drilling a borehole into the wall: positioning a rod into said borehole, said rod including a first rod end inserted into borehole and a second rod end extending from the borehole: attaching an adapter on the second rod end, said adapter defining a adapter groove; mounting a drill rig assembly to an anchor face unit: mounting an anchor clamp assembly to said anchor face unit, said anchor clamp assembly comprising a plurality of jaws movable from an engagement position wherein said plurality of jaws are positioned within said adapter groove to a disengagement position wherein said plurality of jaws are positioned away from said adapter groove: placing said anchor clamp assembly around said adapter groove: moving said plurality of jaws from said disengaged position to said engaged position; and locking said plurality of jaws in said engagement position.

Aspect 29: The method of anchoring a drill rig assembly according to aspect 28, wherein said rod comprises a hollow rod.

Aspect 30: The method of anchoring a drill rig assembly according to aspect 28 or aspect 29, wherein said rod comprises a tubular rod.

Aspect 31: The method of anchoring a drill rig assembly according to aspect 29, wherein said positioning said rod into said borehole comprises: inserting a plurality of resin filled tubes with said within said rod: inserting a rod wiper within said rod, said rod wiper positioned in between said plurality of resin filled tubes and said second rod end: placing said second rod end in communication with said drill rig assembly; inserting said first rod end into said borehole, said first rod end comprising an open end having a plurality of cut outs; rotating said rod using said drill rig assembly; applying pressure inside said rod such that said rod wiper is forced towards said first rod end and said plurality of resin filled tubes are forced through said plurality of cut outs; and continuing to rotate said rod such that resin from said plurality of resin filled tubes is distributed between a rod outer surface and said borehole.

Aspect 32: The method of anchoring a drill rig assembly according to aspect 31, wherein said pressure inside said rod is applied using water pressure.

Aspect 33: The method of anchoring a drill rig assembly according to aspect 31 or aspect 32, further comprising: forming a plurality of rod circumferential grooves around said rod outer surface.

Aspect 34: The method of anchoring a drill rig assembly according to any one of aspects 31-33, further comprising: mounting a drill rod extension between said rod and said drill rig assembly prior to rotating said rod using said drill rig assembly.

Aspect 35: The method of anchoring a drill rig assembly according to any one of aspects 31-34, further comprising: attaching a plurality of actuators to an output of said drill rig assembly; placing said plurality of actuators in communication with said plurality of jaws; and utilizing said plurality of actuators to move said plurality of jaws between said disengaged position and said engaged positon.

Aspect 36: The method of anchoring a drill rig assembly according to aspect 35, wherein said plurality of actuators comprise a plurality of hydraulic actuators attached to a hydraulic output of said drill rig assembly.

Aspect 37: The method of anchoring a drill rig assembly according to claim 35 or claim 36, wherein said attaching a plurality of actuators to an output of said drill rig assembly comprises: attaching a hydraulic valve bank to said plurality of actuators, said drill rig assembly, and a hydraulic oil tank; and controlling said hydraulic valve bank using an actuator flow lever to move said plurality of jaws between said disengaged position and said engaged position.

Aspect 38: The method of anchoring a drill rig assembly according to aspect 37, wherein said plurality of brake elements are attached to said hydraulic output of said drill rig assembly.

Aspect 39: The method of anchoring a drill rig assembly according to aspect 37 or aspect 38, wherein said locking said plurality of jaws in said engagement position comprises: removing hydraulic pressure from a plurality of brake elements in communication with said plurality of jaws, said plurality of brake elements movable between a brake locked position and a brake unlocked position, said plurality of brake elements preventing movement of said plurality of jaws in said brake locked position, said plurality of brake elements biased towards said braked locked position such that removal of said hydraulic pressure locks said plurality of jaws.

Aspect 40: The method of anchoring a drill rig assembly according to aspect 39, wherein said hydraulic valve bank comprises a double sectioned hydraulic valve bank, the method further comprising: attaching said double sectioned hydraulic valve bank to said plurality of brake elements and said drill rig assembly; and controlling said plurality of brake elements using a brake flow lever to move said plurality of brake elements between said brake locked position and said brake unlocked position.

Aspect 41: The method of anchoring a drill rig assembly according to any one of aspects 38-40, wherein said rod comprises a threaded rod portion at said second rod end; and wherein said adapter comprises a threaded adapter portion, said threaded adapter portion removable engaging said threaded rod portion.

Aspect 42: The method of anchoring a drill rig assembly according to any one of aspects 28-41, wherein said attaching an adapter on the second rod end further comprises: engaging a socket adapter having a socket face and a threaded socket end to said drill rig assembly; placing said socket face in communication with a socket interface formed in said adapter; and rotating said socket adapter using said drill rig assembly such that said threaded adapter portion engages said threaded rod portion.

Aspect 43: The method of anchoring a drill rig assembly according to aspect 42, further comprising: attaching a threaded socket end of said socket adapter to a drill rod extension: attaching said drill rod extension to said drill rig assembly; and using said drill rig assembly to rotate said drill rod extension and said socket adapter such that said threaded adapter portion engages said threaded rod portion.

Aspect 44: A method of anchoring a drill rig assembly to a formation comprising: drilling a borehole into the formation: installing at least one anchor mount to said borehole; mounting a drill rig assembly to an anchor face unit; and securing said anchor face unit to said anchor mount.

Aspect 45: The method according to aspect 44, further wherein said installing at least one anchor mount to said borehole comprises: installing at least one casing within said borehole: wherein said securing said anchor face unit to said anchor mount comprises coupling said anchor face unit to said casing.

Aspect 46: The method according to aspect 45, wherein said casing comprises a plurality of casings, wherein coupling said anchor face unit to said casing comprises coupling each sassing of said plurality of casings to said anchor face unit with a respective tie member.

Aspect 47: The method according to aspect 46, wherein said tie member comprises a turnbuckle, wherein coupling said anchor face unit to said casing comprises adjusting an operative length of a turnbuckle of said tie member.

Aspect 48: The method according to aspect 46 or aspect 47, wherein said casing comprises a central casing, wherein coupling said anchor face unit comprises positioning said anchor face unit so that said anchor face unit at least partially surrounds a central casing.

Aspect 49: The method according to aspect 47 or aspect 48, further comprising welding said anchor face unit to said central casing.

Aspect 50: The method according to aspect 49, wherein said anchor face unit comprises: a main body having an underside and defining a bolt hole pattern: a flange defining a plurality of threaded members that are receivable in to respective holes of the bolt hole pattern, wherein the flange is coupled to the underside of the main body; and a retainer ring, wherein welding said anchor face unit to said central casing comprises welding said retainer ring to said central casing.

Aspect 51: The method according to aspect 50, further comprising welding said retainer ring to said flange.

Aspect 52: The method according to aspect 51, further comprising cutting the weld between said retainer ring and said central casing.

Aspect 53: The method according to aspect 51 or aspect 52, wherein said anchor face unit comprises: a main body; and a retaining ring, wherein welding said anchor face unit to said central casing comprises welding said retaining ring to said central casing.

Aspect 54: The method according to any one of aspects 44-53, wherein said anchor face unit has a central axis and a bottom surface, wherein said anchor face unit comprises at least one fin that extends outwardly from said central axis.

Aspect 55: The method according to aspect 54, wherein said at least one fin comprises a plurality of fins.

Aspect 56: The method according to aspect 54 or aspect 55, further comprising: installing a ground anchor below a ground surface; and coupling said anchor face unit to said ground anchor.

Aspect 57: The method according to aspect 56, wherein said coupling said anchor face unit to said ground anchor comprises coupling a tie rod to said anchor face unit with a nut, wherein said tie rod extends from said ground anchor to said anchor face unit.

Aspect 58: The method according to any one of aspects 44-57, wherein said installing at least one anchor mount to said borehole comprises: positioning a rod into said borehole, said rod including a first rod end inserted into borehole and a second rod end extending from the borehole, and attaching an adapter on the second rod end, said adapter defining an adapter groove; and wherein said securing said anchor face unit to said anchor mount comprises: mounting an anchor clamp assembly to said anchor face unit, said anchor clamp assembly comprising a plurality of jaws movable from an engagement position wherein said plurality of jaws are positioned within said adapter groove to a disengagement position wherein said plurality of jaws are positioned away from said adapter groove: placing said anchor clamp assembly around said anchor: moving said plurality of jaws from said disengaged position to said engaged position; and locking said plurality of jaws in said engagement position.

Aspect 59: The method according to aspect 58, wherein said rod comprises a hollow rod.

Aspect 60: The method according to aspect 59, wherein said positioning said rod into said borehole comprises: inserting a plurality of resin filled tubes with said within said rod: inserting a rod wiper within said rod, said rod wiper positioned in between said plurality of resin filled tubes and said second rod end: placing said second rod end in communication with said drill rig assembly; inserting said first rod end into said borehole, said first rod end comprising an open end having a plurality of cut outs: rotating said rod using said drill rig assembly; applying pressure inside said rod such that said rod wiper is forced towards said first rod end and said plurality of resin filled tubes are forced through said plurality of cut outs; and continuing to rotate said rod such that resin from said plurality of resin filled tubes is distributed between a rod outer surface and said borehole.

Aspect 61: The method of anchoring a drill rig assembly according to aspect 60, further comprising: attaching a plurality of actuators to an output of said drill rig assembly; placing said plurality of actuators in communication with said plurality of jaws; and utilizing said plurality of actuators to move said plurality of jaws between said disengaged position and said engaged positon.

Aspect 62: The method of anchoring a drill rig assembly according to aspect 61, wherein said attaching a plurality of actuators to an output of said drill rig assembly comprises: attaching a hydraulic valve bank to said plurality of actuators, said drill rig assembly, and a hydraulic oil tank; and controlling said hydraulic valve bank using an actuator flow lever to move said plurality of jaws between said disengaged position and said engaged position.

Aspect 63: The method of anchoring a drill rig assembly according to aspect 61, wherein said attaching a plurality of actuators to an output of said drill rig assembly comprises: attaching a hydraulic valve bank to said plurality of actuators, said drill rig assembly, and a hydraulic oil tank; and controlling said hydraulic valve bank using an actuator flow lever to move said plurality of jaws between said disengaged position and said engaged position.

Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, certain changes and modifications may be practiced within the scope of the appended claims.

Claims

1. An anchor assembly for mounting a drill rig assembly to a wall of a formation within which a borehole is formed, the anchor assembly comprising:

a rod mountable within the borehole, said rod including a first rod end inserted into the borehole and a second rod end extending from the borehole;

an adapter positioned on the second rod end, said adapter defining an adapter groove;

an anchor face unit comprising a plurality of drill rig assembly mounting features; and

an anchor clamp mounted to said anchor face unit, said anchor clamp comprising a plurality of jaws movable from an engagement position wherein said plurality of jaws are positioned within said adapter groove to a disengagement position wherein said plurality of jaws are positioned away from said adapter groove.

2. The anchor assembly according to claim 1, wherein said rod comprises a hollow rod.

3. (canceled)

4. The anchor assembly according to claim 1, wherein said rod comprises a threaded rod portion at said second rod end; and wherein said adapter comprises an threaded adapter portion, said threaded adapter portion removably engaging said threaded rod portion.

5. The anchor assembly according to claim 2, wherein said first rod end comprises an open end having a plurality of cutouts.

6. The anchor assembly according to claim 5, further comprising:

a plurality of resin filled tubes positioned within said rod; and

a rod wiper positioned within said rod in between said plurality of resin filled tubes and said second rod end, said rod wiper movable between a resin storage positon and a resin dispersal position, said rod wiper when in said resin dispersal position forcing said plurality of resin filled tubes through said plurality of cutouts to disperse a resin between said rod and the borehole.

7. The anchor assembly according to claim 6, wherein said rod comprises a plurality of rod circumferential grooves formed on a tubular rod outer surface.

8. (canceled)

9. The anchor assembly according to claim 1, further comprising:

a plurality of actuators in communication with said plurality of jaws, said plurality of actuators configured to move said plurality of jaw between said engagement position and said disengagement position.

10. The anchor assembly according to claim 9, further comprising:

an actuator proximity switch; and

an actuator indicator light;

wherein said actuator indicator light operates to identify one of said plurality of jaws are in said engagement position.

11. (canceled)

12. (canceled)

13. The anchor assembly according to claim 9, further comprising:

a plurality of brake elements in communication with said plurality of jaws, said plurality of brake elements movable between a brake locked position and a brake unlocked position, said plurality of brake elements preventing movement of said plurality of jaws in said brake locked position.

14. The anchor assembly according to claim 13, wherein each of said plurality of brake elements comprises:

a brake actuator wedge;

a spring element in communication with said brake actuator wedge; and

a brake pad wedge in communication with said brake actuator wedge and one of said plurality of actuators;

wherein said spring element biases said brake actuator wedge into said brake pad wedge to frictionally engage one of said plurality of actuators.

15. (canceled)

16. (canceled)

17. (canceled)

18. The anchor assembly according to claim 13, further comprising:

a brake proximity switch; and

a brake indicator light;

wherein said brake indicator light operates to identify said brake is in said brake locked position.

19. The anchor assembly according to claim 13, wherein said plurality of brake elements are moved from said brake locked position to said brake unlocked position by a hydraulic brake actuator.

20. (canceled)

21. (canceled)

22. The anchor assembly according to claim 1, wherein anchor clamp comprises:

a clamp base plate;

a pair of clamp side walls affixed to said clamp base plate and forming a slide channel; and

a clamp cover plate affixed to said pair of claim side walls and covering said slide channel;

wherein said plurality of jaws are slidably retained within said slide channel.

23. The anchor assembly according to claim 22, further comprising:

a plurality of actuators mounted to said clamp base plate and in communication with said plurality of jaws, said plurality of actuators configured to slide said plurality of jaws inside said slide channel between said engagement position and said disengagement position.

24. The anchor assembly according to claim 23, wherein said plurality of actuators comprises a plurality of hydraulic actuators.

25. (canceled)

26. The anchor assembly according to claim 4, wherein said adapter further comprises a socket interface opposite said threaded adapter portion, and wherein the anchor assembly further comprises:

a socket adapter having a socket face configured to engage said socket interface and a threaded socket end configured to engage a drill rod tubular extension.

27. (canceled)

28. A method of anchoring a drill rig assembly to a wall of a formation comprising:

drilling a borehole into the wall;

positioning a rod into said borehole, said rod including a first rod end inserted into borehole and a second rod end extending from the borehole;

attaching an adapter on the second rod end, said adapter defining a adapter groove;

mounting a drill rig assembly to an anchor face unit;

mounting an anchor clamp assembly to said anchor face unit, said anchor clamp assembly comprising a plurality of jaws movable from an engagement position wherein said plurality of jaws are positioned within said adapter groove to a disengagement position wherein said plurality of jaws are positioned away from said adapter groove;

placing said anchor clamp assembly around said adapter groove;

moving said plurality of jaws from said disengaged position to said engaged position; and

locking said plurality of jaws in said engagement position.

29. The method of anchoring a drill rig assembly according to claim 28, wherein said rod comprises a hollow rod.

30. (canceled)

31. The method of anchoring a drill rig assembly according to claim 29, wherein said positioning said rod into said borehole comprises:

inserting a plurality of resin filled tubes with said within said rod;

inserting a rod wiper within said rod, said rod wiper positioned in between said plurality of resin filled tubes and said second rod end;

placing said second rod end in communication with said drill rig assembly;

inserting said first rod end into said borehole, said first rod end comprising an open end having a plurality of cut outs;

rotating said rod using said drill rig assembly;

applying pressure inside said rod such that said rod wiper is forced towards said first rod end and said plurality of resin filled tubes are forced through said plurality of cut outs; and

continuing to rotate said rod such that resin from said plurality of resin filled tubes is distributed between a rod outer surface and said borehole.

32. The method of anchoring a drill rig assembly according to claim 31, wherein said pressure inside said rod is applied using water pressure.

33. (canceled)

34. (canceled)

35. The method of anchoring a drill rig assembly according to claim 31, further comprising:

attaching a plurality of actuators to an output of said drill rig assembly;

placing said plurality of actuators in communication with said plurality of jaws; and

utilizing said plurality of actuators to move said plurality of jaws between said disengaged position and said engaged positon.

36. (canceled)

37. (canceled)

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. The method of anchoring a drill rig assembly according to claim 28, wherein said attaching an adapter on the second rod end further comprises:

engaging a socket adapter having a socket face and a threaded socket end to said drill rig assembly;

placing said socket face in communication with a socket interface formed in said adapter; and

rotating said socket adapter using said drill rig assembly such that said threaded adapter portion engages said threaded rod portion.

43. The method of anchoring a drill rig assembly according to claim 42, further comprising:

attaching a threaded socket end of said socket adapter to a drill rod extension:

attaching said drill rod extension to said drill rig assembly; and

using said drill rig assembly to rotate said drill rod extension and said socket adapter such that said threaded adapter portion engages said threaded rod portion.

44. A method of anchoring a drill rig assembly to a formation, the method comprising:

drilling a borehole into the formation;

installing at least one anchor mount to said borehole;

mounting a drill rig assembly to an anchor face unit; and

securing said anchor face unit to said anchor mount,

wherein said installing at least one anchor mount to said borehole comprises: positioning a rod into said borehole, said rod including a first rod end inserted into borehole and a second rod end extending from the borehole, and attaching an adapter on the second rod end, said adapter defining an adapter groove; and

wherein said securing said anchor face unit to said anchor mount comprises: mounting an anchor clamp assembly to said anchor face unit, said anchor clamp assembly comprising a plurality of jaws movable from an engagement position wherein said plurality of jaws are positioned within said adapter groove to a disengagement position wherein said plurality of jaws are positioned away from said adapter groove; placing said anchor clamp assembly around said anchor; moving said plurality of jaws from said disengaged position to said engaged position; and locking said plurality of jaws in said engagement position.

45. The method according to claim 44, further wherein said installing at least one anchor mount to said borehole comprises:

installing at least one casing within said borehole:

wherein said securing said anchor face unit to said anchor mount comprises coupling said anchor face unit to said casing.

46. The method according to claim 45, wherein said casing comprises a plurality of casings, wherein coupling said anchor face unit to said casing comprises coupling each casing of said plurality of casings to said anchor face unit with a respective tie member.

47. (canceled)

48. (canceled)

49. (canceled)

50. (canceled)

51. (canceled)

52. (canceled)

53. (canceled)

54. The method according to claim 44, wherein said anchor face unit has a central axis and a bottom surface, wherein said anchor face unit comprises at least one fin that extends outwardly from said central axis.

55. (canceled)

56. The method according to claim 54, further comprising:

installing a ground anchor below a ground surface; and

coupling said anchor face unit to said ground anchor.

57. (canceled)

58. (canceled)

59. The method according to claim 44, wherein said rod comprises a hollow rod.

60. The method according to claim 59, wherein said positioning said rod into said borehole comprises:

inserting a plurality of resin filled tubes with said within said rod;

inserting a rod wiper within said rod, said rod wiper positioned in between said plurality of resin filled tubes and said second rod end;

placing said second rod end in communication with said drill rig assembly;

inserting said first rod end into said borehole, said first rod end comprising an open end having a plurality of cut outs;

rotating said rod using said drill rig assembly;

applying pressure inside said rod such that said rod wiper is forced towards said first rod end and said plurality of resin filled tubes are forced through said plurality of cut outs; and

continuing to rotate said rod such that resin from said plurality of resin filled tubes is distributed between a rod outer surface and said borehole.

61. The method of anchoring a drill rig assembly according to claim 60, further comprising:

attaching a plurality of actuators to an output of said drill rig assembly;

placing said plurality of actuators in communication with said plurality of jaws; and

utilizing said plurality of actuators to move said plurality of jaws between said disengaged position and said engaged positon.

62. The method of anchoring a drill rig assembly according to claim 61, wherein said attaching a plurality of actuators to an output of said drill rig assembly comprises:

attaching a hydraulic valve bank to said plurality of actuators, said drill rig assembly, and a hydraulic oil tank; and

controlling said hydraulic valve bank using an actuator flow lever to move said plurality of jaws between said disengaged position and said engaged position.

63. (canceled)