Patent Application
20090008112
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1. Field of the Invention
The field of the invention relates to drilling rigs for the drilling of oil, gas and other wells, and in particular to drilling rigs having modular components which are capable of being moved from well to well in formation.
2. Description of the Related Art
In drilling oil and gas wells, it is well known that almost innumerable components are essential to actually drilling the well. For example, a basic drilling rig structure having a mast housing rotational equipment such as a top drive is necessary to direct the drill pipe and casing strings into the borehole as drilling takes place. In order to circulate the drill cuttings out of the borehole during drilling, it is necessary to circulate drilling “mud” or fluid down the drill pipe and upwardly through the annulus between the drill pipe and the casing. Providing the mud circulation system requires powerful mud pumps, fluid storage equipment, and particle separation equipment to remove the drill cuttings and prepare the drilling mud for recirculation.
The top drive and most other well equipment are electrically powered, thus requiring significant power generation equipment. For example, referring to FIG. 2 of U.S. Pat. No. 4,899,832, the drilling unit includes massive pipe storage units, a mud mixing and supply unit, first and second electrical power supply units, a drilling mud return unit, a fuel unit, a water supply unit, a cement unit and a command center, which must be set up at each drill site, and then transported on truck tractors to the next well site and then set up again in the necessary arrangement for drilling activity. Typically in the U.S., such equipment must be broken down into loads which meet allowable weight and size restrictions for travel along state and federal roads.
In some foreign countries where the drilling sites are located on remote land such as in the Artic or in the deserts of the Mid-East, because the drilling rigs and associated equipment do not have to travel along highways, it is known to use portable drilling rigs in which the drilling equipment is housed in travel modules. For example, Dreco, now a part of National Oil Well Varco, utilized modular type construction of the drilling rig and drilling equipment such that the modules could be disassembled and loaded onto trucks, islands, barges, and/or caissons for travel between well sites. The Dreco portable rigs utilized giant wheel assemblies, which included all wheel drive, to move the rigs over the country side, but insofar as known, the modular components were moved without attempt to maintain the modules in drilling formation or arrangement during travel. For example, Dreco's Desert Rigs were moved from well to well in a single line formation using a combination of truck tractor and wheel units mounted directly with the drilling modules. Once a new drill site was reached, while major equipment did not need to be removed during transportation, it was then necessary to demobilize the modules and arrange them into the formation necessary to begin drilling operations.
A mobile drilling system is provided which includes a plurality of drilling system modules capable of coordinated movement between well or other drilling sites. The mobile drilling system includes modules, such as a rig module, a power module and a pump module, which are initially positioned in a drilling formation or arrangement with respect to each other for the drilling of a first oil and gas well. After the completion of that well, the modules are then movable to a new location such as another well site. During the movement between the well sites, the drilling system modules are maintained in a formation which is substantially the same as the formation of the modules as used on the first drilling site. In order to accomplish this coordinated movement, each of the drilling system modules has wheel assemblies mounted therewith which are steerable, preferably simultaneously, in order to guide each of the modules during movement between well sites. Each of the modules further includes a propulsion system mounted with the module in order to drive the wheel assemblies attached to the modules in a predesignated direction and at a predesignated velocity, which can vary depending upon conditions. A steering system is in operative engagement with the propulsion system and the wheel assemblies of each module so that each module has a propulsion and steering system for moving the module between drilling sites. A position feedback system is mounted with each of the modules. The feedback position system includes sensors for detecting the relative position of each module with respect to the other modules during movement from the initial well site to subsequent drilling sites. The feedback position system cooperates with the propulsion system and the steering system in order to adjust the position of the modules with respect to each other to substantially maintain the initial drilling formation of the drilling system during such movement or travel between well sites.
One type of wheel assembly utilized is a dual or two-wheel assembly which is driven by the propulsion system and rotated or turned by the steering system. The wheel assembly includes one or more hydraulic motors or other types of motors to propel the rig at a predesignated or desired velocity. One of the wheels is turned or rotated by the steering system based upon feedback from the position feedback system, with the other wheel being in a mechanical, linked relationship to the first wheel so that both wheels rotate and move in unison. For heavier modules, multiple sets of four wheels are provided with driving motors and steering mechanism for moving the four-wheel assemblies into a particular direction as well as for driving the wheels at a desired velocity. It is within the scope of the invention to vary the number of wheels depending upon design and environmental conditions.
Using this structure, an operator is able to initially set up his rigs at a particular arrangement and thereafter continue that arrangement, including live connections for power and fluid transfer between the modules, during travel of the group of rig modules to a new location.
A better understanding of the present invention can be obtained when the following detailed description of the disclosed embodiments is considered in conjunction with the following drawings in which:
a illustrates an enlarged cross-sectional side view of the dual drive wheel assembly from either the power module or the mud pump module.
b illustrates an enlarged cross-sectional top view of the dual drive wheel assembly from either the power module or mud pump module.
a illustrates a cross-sectional top view of a quad set of drive wheel assemblies from the rig module.
b illustrates a cross-sectional side view of a quad set of drive wheel assemblies from the rig module.
The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope of the present invention.
While the invention is described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the invention's construction and the arrangement of its components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification.
Referring to the drawings in detail,
In one embodiment of the present invention, each of the three drilling modules 1, 2 and 3, are self-propelled with the rig module being the master and the mud pump and power modules 1 and 2 being the slaves to the rig module 3.
In one embodiment of the present invention, the self-propelled power module 1 includes three generators, 1a, 1b and 1c, which generate electricity to drive various components of the drilling rig. The power module also includes a hydraulic power unit 1d, which provides the hydraulic power driving the rotation and turning of the wheel assemblies 1e. The cable booms 1f and 1g, harness the electrical and hydraulic cables from the power module 1 to the mud pump and rig modules 2 and 3. All cables and utilities stay intact and fully functioning during well-to-well transportation of the drilling rig.
In one embodiment of the present invention, the mud pump module 2 includes two mud pumps 2a and 2b and a plurality of round mud tanks 2c. The mud pump module 2 also includes a hydraulic power unit 2d, as well as centrifugal pumps 2e and 2f. The hydraulic power unit 2d provides hydraulic fluid which supplies power to the wheel assemblies for turning of the wheels of the wheel assemblies. It should be appreciated that any type of power may be used to power the turning of the wheels. For example, electric motors may be preferable to hydraulic power in some instances. The centrifugal pumps 2e and 2f provide for circulating and transferring mud from tank to tank and for transferring mud from the tanks to the mud pumps. Additionally, the mud pump module 2 includes a plurality of mixing hoppers 2g which mix the drilling fluid. The dual wheel drive assemblies 1e are at each of the four corners of the generally rectangular (as viewed in
The rig module 3, in one embodiment, has four quad set drive wheel assemblies 3e wherein one quad set drive wheel assembly is located at each of the four corners of the rig module 3, which is generally rectangular as viewed in
The wheel assemblies of each of the three modules 1, 2, and 3, each include fully load-equalized tires and are controlled by a control system extending from a control center on each wagon. The controls provide for coordinated turning of each wheel in the wheel assemblies and provide feedback of the relative position of the power and mud pump modules, 1 and 2, with respect to the rig module 3, so that the modules can be moved in formation and spatially coordinated. For example, during drilling of an initial well, the formation or spatial relationship of the power module 1, mud pump module 2 and rig module 3 is illustrated in
Other mobile components of a drilling rig may include a headquarters trailer, a fuel trailer, a reserve mud tank, a water tank and a powered catwalk. These components are not illustrated in the drawings but may be moved via a truck, trailer, or self-propelled module.
a is an enlarged top view, partly in cross-section of the dual drive wheel assembly 1c utilized on both the power module 1 and the mud pump module 2 as contemplated in one embodiment of the present invention. Each of the dual drive wheel assemblies 1e includes two wheels 4a and 4b, two hydraulic wheel motors 4c and 4j, a steering linkage 4d, a steering knuckle 4e, a steering actuator arm 4f, a turning cylinder assembly 4g, and hydraulic fluid lines 4h and 4m, which power the steering and rotation of each dual drive wheel assembly 1e. The hydraulic lines 4h and 4m are controlled by a control valve 4i which is controlled by the hydraulic control system as depicted in
Referring to
In operation, each dual drive wheel assembly 1e, in one preferred embodiment, operates via hydraulic pressure communicated to the turning cylinder assembly 4g and the hydraulic wheel motors 4c and 4j in order to turn and rotate the wheels 4a and 4b. In order to turn the wheels 4a and 4b to the right (toward top of
a illustrates a cross-sectional enlarged top view partly in schematic of the quad set of drive wheel assemblies 3e from the rig module 3. The quad set 3e is comprised of two interconnected dual sets or assemblies of wheels 6h and 6i which are driven by hydraulic motors (6p, 6q, 6r and 6s in
b illustrates a cross-sectional enlarged side view of the quad set of drive wheel assemblies 3e from the rig module 3. The walking beam 6e interconnects the first and second wheel assemblies 6h and 6i. The walking beam 6e is pivotally connected (about pivot point 11c) to the frame 11 for pivotal movement about a horizontal axis 11a. The wheel assembly is also pivotally connected to the frame 11 for pivotal movement about the clevis, another horizontal axis (in the plane of movement of the tires moving vertically, not shown). The two pivot points about horizontal axes serve to ensure that all four tires are always touching the ground 11b even if the ground 11b is uneven.
In operation, an operator controls the movement of the rig module 3 via a joystick or some other steering or control mechanism (not shown). Position information from the feedback sensor system 7a-7f is communicated to programmable logic chip or other computer element to compute the relative position of each of rigs 1-3, which information is provided to the operator control station 8k which sends feedback signals to each of the control valves 6m on rig 3, as well as to control valves 1h on rig 1 and control valves 2h on rig 2. The operator control station 8k sends feedback signals to each of the drive wheel assemblies 3e through these various control valves to modify the relative position of each rig with respect to the other rigs in order for the formation of the modules to remain substantially unchanged, such as from the arrangement of the modules during drilling of an earlier well, during travel to a new well site. For example, in one preferred embodiment, if the operator desires to make a right-hand turn, the operator control station 8k sends a signal to each of the control valves of each rig in order to send hydraulic pressure to each of the corresponding turning cylinders (not shown) within the drive assemblies (see
It should be noted that the steering controls utilized in conjunction with the dual wheel assemblies 1e and the quad wheel assemblies 3e enable all the wheels to be turned in the same direction substantially simultaneously, such that subsequent driving or propulsion of the turned wheels provides for crab-like or angled movement of these giant pieces of equipment.
The linear position sensors 7a, 7b, 7c, 7d, 7e, and 7f sense the position of each of the power and mud pump modules 1 and 2 in reference to the rig module 3. Signals from these linear position sensors are sent to the operator control stations 8k, 9a, and 10a of each of the modules. The programmable logic controllers 8l, 9b, 10b then calculate the actions within each of the power module 1 and mud pump module 2 that must be completed in order for these modules to travel in formation or predesignated spatial position with the travel of the rig module 3.
For example, in one preferred embodiment, if the operator desires to turn the three self-propelled modules to the right, the rig operator will instruct the rig module 3 to make a right-hand turn and a signal will be sent to the operator control station 8k, which sends a hydraulic signal to each of the control valves 6m, which sends a hydraulic signal to each of the four quad sets of drive wheel assemblies 3e. The piston rods of the turning cylinder assemblies (not shown) within the four quad sets of drive wheel assemblies 3e will expand in order to rotate or turn each of the wheel sets. The linear position sensors 7a, 7b, 7c, 7d, 7e and 7f will sense if the rig module 3 has changed position moved in reference to the power module 1 and the mud pump module 2. The position sensors will send a signal to the operator control stations 8k, 9a, and 10a and the programmable logic controllers 9b and 10b will calculate the actions needed to propel and turn the wheel assemblies in the power module 1 and the mud pump module 2 and rig module 3 to maintain the desired formation. Any adjustment to position of each of the rigs may be accomplished automatically utilizing the feedback, propulsion and steering systems, or each operator on each rig may be notified of positional changes to be made on his or her rig such that position adjustment can be accomplished from each rig.
In another embodiment of the present invention, a string or rope will be stretched from the starting location of the rig module 1 to an ending location of that module, which may be the next well site. A camera may be used to monitor the module's location in reference to the string or rope. A monitor may be mounted in the operators' cabin so that the operator can monitor the module's location in reference to the string or rope and make the necessary adjustments. As the operation of the rig wagon 1 moves the rig wagon in the direction of the guide rope, the feedback system, utilizing the positional information derived from the sensors 7a-f, will automatically adjust the speed and position of the power wagon and mud wagon 2 with respect to the rig wagon and each other. The formation of the Rigs 1-3 during movement to a subsequent well site may be substantially the same formation of the rigs 1-3 while drilling the initial well, or any other formation which efficiently allows to rig set-up upon arrival at the next well site. Further, the traveling formation may be designed with an adjustable margin of error in relative positions of the rigs 1-3. For example, the feedback control can be adjusted to allow a predesignated amount of latitude or variation from a designated formation, or arrangement of the rigs. While the position feedback system disclosed utilizes a series of sensors mounted on each of the three rigs to be moved in unison, other feedback systems may be used such as gps (global position satellite) to monitor the relative positions, arrangement or formation of the rigs 1-3 with respect to each other.
While it is a significant advantage to move the well modules in formation, there may be circumstances where it is desirous to move each module 1-3 independently of the other rig modules. For example, if there is a well site location with a plurality of wells and then another well site location with another plurality of wells several miles away from the first plurality of wells, the operator may desire to move each of the modules independently of the others due to obstructions or other operational concerns; and, in that situation, the feedback control system is temporarily deactivated, but can be restarted when it is designed to re-position the rig modules in formation.
