Automated bit handling and changing system and process

Abstract

A drill bit handling and changing system includes a deck wrench assembly mounted on a deck of a mast of a drill rig and arranged to break the bit from a drill pipe of the rig, and a bit changing mechanism slidably disposed on the deck wrench assembly between a standby position and an engaged position where the bit changing mechanism is centered with the drill bit and/or drill pipe. The bit changing mechanism includes a carousel having a plurality of receptacles, at least one of the receptacles being empty to receive a used drill bit and at least two receptacles holding new drill bits to be connected with the drill pipe after the used drill bit is removed from the drill string. The bit changing mechanism includes a slewing drive arranged to rotate the carousel to present an empty receptacle or a new drill bit to the drill pipe.

What is claimed is: 
     
         1 . A drill bit handling and changing system for a drill rig, the system comprising:
 a deck wrench assembly mounted on a deck of a mast of the drill rig, the deck wrench assembly being arranged to break the drill bit from a drill pipe of the rig; and   a bit changing mechanism slidably disposed on the deck wrench assembly between a standby position and an engaged position where the bit changing mechanism is centered with the drill bit and/or drill pipe, the bit changing mechanism including a carousel having a plurality of receptacles, at least one of the receptacles being empty to receive a used drill bit and at least two receptacles holding new drill bits to be connected with the drill pipe after the used drill bit is removed from the drill string, wherein the bit changing mechanism includes a slewing drive arranged to rotate the carousel to present an empty receptacle or a new drill bit to the drill pipe.   
     
     
         2 . The system of  claim 1 , wherein the bit changing mechanism includes a plurality of bit breaker plates attached to the carousel, each plate being arranged to cover a respective receptable. 
     
     
         3 . The system of  claim 2 , wherein each of the plurality of plates includes an opening shaped to accommodate a shape and size of the drill bit being removed or attached. 
     
     
         4 . The system of  claim 1 , wherein the bit changing mechanism includes a cover assembly. 
     
     
         5 . The system of  claim 1 , further comprising a break-out wrench pivotally mounted on the mast to engage the drill pipe. 
     
     
         6 . A method of changing a drill bit of a drill rig, the method comprising the steps of:
 providing a drill bit handling and changing system according to  claim 1 ;   sliding the bit changing mechanism along the deck wrench assembly to position the bit changing mechanism underneath a raised, used drill bit in the engaged position;   positioning an empty receptacle of the carousel underneath the used bit;   lowering the drill bit to position the used drill bit in the receptacle;   pivoting a break-out wrench mounted on the mast to engage the drill pipe;   breaking a connection between the used drill bit and the drill pipe;   unclamping the break-out wrench and raising the drill pipe to uncouple the drill bit from the drill pipe;   sliding the bit changing mechanism with the used drill bit located in the receptacle to the standby position on the deck wrench assembly;   rotating the carousel to position a receptacle holding the new unused bit toward the drill pipe;   sliding the bit changing mechanism with the new, unused drill bit located in the receptacle to the engaged position on the deck wrench assembly centered with the drill pipe;   lowering the drill pipe and rotating the drill pipe to attach the new, unused drill bit to the drill pipe.   
     
     
         7 . The method of  claim 6 , wherein the used drill bit is lowered through the opening of the plate into the receptacle. 
     
     
         8 . The method of  claim 6 , further comprising the step of lowering the drill pipe and the attached drill bit through an opening in the deck wrench assembly.