Patent Application
20140262518
The present disclosure relates in general to drilling rigs, and in particular, to assembling a drilling rig using a self-elevating substructure, rig floor, and mast.
While various equipment is used in exploration and production operations, such as for oil and gas, accidents sometimes occur with existing drilling rig equipment and operations are otherwise inefficient when numerous personnel are required. Thus, there is a need for improved drilling rig equipment as further disclosed herein.
The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.
Referring to
Referring to
In one embodiment, the apparatus 10 includes a drive carriage system 70 having a carriage frame 75 attached to the rig floor 30, a pinion drive carriage 80 attached to the carriage frame 75, and a stabilizer frame 85 attached to the rig floor 30. In one embodiment, the carriage frame 75 is attached to the rig floor 30 and extends vertically from the rig floor 30. In one embodiment, carriage frame 75 has an upper portion and an opposing lower portion connected to the rig floor 30. In one embodiment, the pinion drive carriage 80 is attached to the lower portion of the carriage frame 75 or the upper portion of the carriage frame 75. In one embodiment, the pinion drive carriage 80 can be attached to the carriage frame 75 using a pin system, bolts, screws, or any other type(s) of adequate fastener. In one embodiment, the pinion drive carriage 80 extends in a vertical direction parallel or at least substantially parallel with the longitudinal axis of the wellbore 68 and or the axis 32, and has a plurality of electric motors 90a, 90b, 90c, and 90d. Each pinion from a plurality of pinions 95a, 95b, 95c, and 95d is operably coupled to the respective electric motor 90a, 90b, 90c, and 90d. In one embodiment, each pinion from the plurality of pinions 95a, 95b, 95c, and 95d is adapted to engaged teeth of a rack 100 located on a longitudinal edge of a mast section 105a, 105b, 105c, 105d or 105e (the mast sections 105b, 105c, 105d, and 105e are not shown). In one embodiment, the electric motors 90a, 90b, 90c, and 90d cause the respective pinions operably coupled thereto to rotate and engage teeth of the rack 100. As a result, the mast sections 105a, 105b, 105c, 105d, and or 105e and the pinion drive carriage 80 move relative to each other. That is, if the pinion drive carriage 80 is attached to the rig floor 30, then activation of the electric motors 90a, 90b, 90c, and 90d causes the respective pinions operably coupled thereto to rotate and engage the teeth of the rack 100 so that the mast sections 105a, 105b, 105c, etc., move in a vertical direction relative to the pinion drive carriage 80. In one embodiment, if the mast section 105a, 105b, 105c, 105d or 105e is attached to the rig floor 30, then activation of the electric motors 90a, 90b, 90c, and 90d causes the respective pinions operably coupled thereto to rotate and engage the teeth of the rack 100 so that the pinion drive carriage 80 moves in a vertical direction relative to the mast section 105a, 105b, 105c, 105d, or 105e. In one embodiment, the mast sections 105a, 105b, 105c, 105d, and 105e extend along a first axis and move in a vertical direction along the first axis upon actuation of the plurality of motors 90a, 90b, 90c, and 90d. One embodiment of the pinions 95a, 95b, 95c, 95d, carriage 80, and motors 90a, 90b, 90c, and 90d are described in U.S. Application No. 61/646,686, which is hereby fully incorporated herein by express reference thereto. In one embodiment, multiple pinion drive carriages 80 can be used, including on an opposite side of the mast 105 by forming another vertical support as a second rack like rack 100. In another embodiment, an additional or alternative pinion drive carriage may be arranged in a vertical position relative to the depicted pinion drive carriage 80, such as below it under the rig floor 30. In one embodiment, the stabilizer frame 85 is attached to the rig floor 30 and extends vertically or at least substantially vertically therefrom. In one embodiment, the stabilizer frame 85 has a support extending vertically and parallel or at least substantially with the axis of the wellbore 68 and or the axis 32. In one embodiment, the stabilizer frame 85 engages and stabilizes the mast sections 105a, 105b, 105c, 105d, etc.
In one embodiment, the apparatus 10 also includes a frame moving system or a platform raising system 110 positioned or arranged relative to the wellbore 68. In one embodiment, the platform raising system 110 has a sub skid 115 and a plurality of actuators 120. In one embodiment, the sub skid 115 is movable and supports the plurality of actuators 120. In one embodiment, the sub skid 115 is rectangular, while in others it is square, trapezoidal, a parallelogram, or other quadrilateral shape. In another embodiment, the sub skid 115 may be any shape that is sufficiently sized to fit between the sub boxes while permitting the plurality of actuators 120 to be disposed over the sub skid 115. In one embodiment, the plurality of actuators 120 typically extends vertically, or in a vertical direction, from the sub skid 115. That is, each longitudinal axis of the plurality of actuators 120 is typically parallel or at least substantially parallel with the axis of the wellbore 68 and or the axis 32. In an exemplary embodiment, the plurality of actuators 120 are, or include, telescoping, hydraulic cylinders. In several exemplary embodiments, each of the actuators of the plurality of actuators 120 is, includes, or is part of, a hydraulic actuator, an electromagnetic actuator, a pneumatic actuator, a linear actuator, and/or any combination thereof. When actuated, each of the plurality of actuators 120 applies a force in a vertical direction, or in at least substantially vertical direction. In one embodiment, the plurality of actuators 120 extend or retract their respective lengths along a vertical or at least substantially vertical axis. In one embodiment, each actuator of the plurality of actuators 120 has one or more couplings 122 (shown in
In one embodiment, the drilling rig 15 includes a mast 105 including the mast sections 105a, 105b, 105c, 105d, and 105e. In one embodiment, the mast sections 105a, 105b, 105c, 105d, and 105e are temporarily attached together to form the mast 105. In one embodiment, the mast sections 105a, 105b, 105c, 105d, and 105e are temporarily attached together to form the mast 105 using a bolt and pin system, wherein an opening on a lower section of the mast section 105a and an opening on an upper section of the mast section 105b are attached using a bolt or pin or both (not shown). This permits the methods described herein to be reversed to disassemble the apparatus to facilitate movement thereof to a new wellbore or other location. In one embodiment, however, the mast sections are permanently joined as they are connected. In some embodiments, the mast 105 extends through the opening 65. In one embodiment, the mast 105 is coupled to the rig floor 30.
In an exemplary embodiment, as illustrated in
At step 205 and as shown in
At step 210 and as shown in
At step 215 and as shown in
At step 220 and as shown in
At step 225 and as shown in
At step 230 and as shown in
At step 235 and as shown in
At step 240, the plurality of actuators 120 are extended so that the couplings 122 engage the rig floor 30. In one embodiment, the plurality of actuators 120 are extended so that a vertical force is applied to the rig floor 30, lifting or raising the rig floor 30 and the upper sub boxes 35a and 35b to a first position. In one embodiment, the first position is a position at which the middle sub boxes 40a and 40b may be arranged below the upper sub boxes 35a and 35b, respectively. In one embodiment, the plurality of actuators 120 are extendable to at least a first height corresponding to the first position.
At step 245, the middle sub boxes 40a and 40b are arranged below the upper sub boxes 35a and 35b, respectively. That is, the middle sub box 40a is arranged below the upper sub box 35a and the middle sub box 40b is arranged below the upper sub box 35b. In one embodiment, the middle sub boxes 40a and 40b are arranged below the upper sub boxes 35a and 35b so that the middle sub boxes 40a and 40b may be attached to the upper sub boxes 35a and 35b, respectively, upon the lowering of the upper sub boxes 35a and 35b.
At step 250, and as shown in
At step 255, and as shown in
At step 260, the lower sub boxes 45a and 45b are arranged below the middle sub boxes 40a and 40b, in a similar manner to that which the middle sub boxes 40a and 40b are arranged below the upper sub boxes 35a and 35b at step 245.
At step 265, and as shown in
At step 270, the plurality of actuators 120 are retracted to disengage from the rig floor 30 and the platform raising system 110 is be removed from below the rig floor 30.
At step 275 and as shown in
In an alternative embodiment, step 275 is omitted and the walking system 228 is included in the lower sub boxes 45a and 45b, the middle sub boxes 40a and 40b, or the upper sub boxes 35a and 35b.
At step 280 and as shown in
At step 285 and as shown in
At step 290 and as shown in
At step 295 and as shown in
At step 300 and as shown in
At step 305 and as shown in
At step 310 and as shown in
At step 315 and as shown in
At step 320 and as shown in
At step 325, the mast section 105e is arranged on the mast skid 230 below the rig floor 30 in a vertically or typically vertical position below the mast section 105d. In one embodiment, the mast section 105e is arranged on the mast skid 230 in a manner similar to that which the mast section 105b is arranged on the mast skid 230 at step 280.
At step 330 and as shown in
At step 335 and as shown in
At step 340 and as shown in
At step 345 and as shown in
At step 350 and as shown in
In an alternative embodiment, as illustrated in
At step 355 and as shown in
At step 360 and as shown in
At step 365 and as shown in
At step 370, the mast section 105a is raised, using the pinion drive carriage 80, through the opening 65 and is attached to the rig floor 30. In one embodiment, the mast section 105a is attached to the rig floor 30 using holding locks, a pin system, bolts, screws, or any other type(s) of adequate fastener(s).
At step 375 and as shown in
At step 380, the pinion drive carriage 80 is attached to the carriage frame 75 and the mast section 105a is detached from the rig floor 30. In one embodiment, the upper portion of the pinion drive carriage 80 is attached to the upper portion of the carriage frame 75.
In one embodiment, a method of constructing the platform includes steps 205, 210, 215, 240, 245, 250, 255, 260, 265, and 270.
In one embodiment, a method of constructing the mast 105 includes steps 220-235 and steps 275-350.
In another embodiment, a method of constructing the mast 105 include steps 220, 355-380, 235, and 275-350.
In another embodiment, additional sub boxes as required are attached to the lower sub boxes 45a and 45b in a manner similar to that which the lower sub boxes 45a and 45b are attached to the middle sub boxes 40a and 40b at step 265. In another embodiment, the platform is constructed using only the lower sub boxes 45a and 45b and the middle sub boxes 40a and 40b, the middle sub boxes 40a and 40b and the upper sub boxes 35a and 35b, or the lower sub boxes 45a and 45b and the upper sub boxes 35a and 35. In another embodiment, the platform is constructed using only the lower sub boxes 45a and 45b, the middle sub boxes 40a and 40b, or the upper sub boxes 35a and 35b.
The present disclosure introduces a method including arranging a plurality of actuators into an operating position; arranging a first upper frame and a second upper frame proximate the actuators; attaching a support to the first upper frame and the second upper frame, wherein the support is located above the actuators; extending the actuators to engage the support; extending the actuators to raise the support, the first upper frame, and the second upper frame to a first position; arranging a first middle frame below the first upper frame and a second middle frame below the second upper frame; retracting the actuators to lower the support, the first upper frame, and the second upper frame to a second position; and attaching the first upper frame to the first middle frame and attaching the second upper frame to the second middle frame. In one aspect, the method also includes extending the actuators to raise the support, the first and second upper frames, and the first and second middle frames to a third position; arranging a first lower frame below the first middle frame and a second lower frame below the second middle frame; retracting the actuators to lower the support, the first and second upper frames, and the first and second middle frames to a fourth position; and attaching the first middle frame to the first lower frame and attaching the second middle frame to the second lower frame. In one aspect, each actuator includes a telescoping hydraulic cylinders. In one aspect, the operating position is a position proximate a wellbore. In one aspect, the support is a platform floor. In one aspect, the support includes a back frame, a rear spreader frame, and a setback spreader frame. In one aspect, the first upper frame and the second upper frame are arranged in parallel or at least substantially in parallel. In one aspect, the first upper frame and the second upper frame are arranged on opposing edges of a wellbore site. In one aspect, the actuators are arranged on opposing edges of a wellbore and between the first upper frame and the second upper frame. In one aspect, the actuators are extendable to at least a first height corresponding to the first position at which the first middle frame may be arranged below the first upper frame and the second middle frame may be arranged below the second upper frame; and wherein the actuators are retractable to at least a second height corresponding to the second position at which the first upper frame may be attached to the first middle frame and the second upper frame may be attached to the second middle frame. In one aspect, the actuators are extendable to at least a third height corresponding to the third position at which the first lower frame may be arranged below the first middle frame and the second lower frame may be arranged below the second middle frame; and wherein the actuators are retractable to at least a fourth height corresponding to the fourth position at which the first middle frame may be attached to the first lower frame and the second middle frame may be attached to the second lower frame.
The present disclosure also introduces a method including arranging a first upper frame and a second upper frame substantially in parallel; arranging a frame moving system between the first upper frame and the second upper frame; attaching a support to the first upper frame and the second upper frame; operably coupling the frame moving system to the support; raising, using the frame moving system, the support, the first upper frame, and the second upper frame; arranging a first middle frame under a first upper frame and a second middle frame under the second upper frame; lowering, using the frame moving system, the support, the first upper frame, and the second upper frame; and attaching the first upper frame to the first middle frame and attaching the second upper frame to the second middle frame. In one aspect, the method also includes raising, using the frame moving system, the support, the first and second upper frames, and the first and second middle frames; arranging a first lower frame below the first middle frame and a second lower frame below the second middle frame; lowering, using the frame moving system, the support, the first and second upper frames, and the first and second middle frames; and attaching the first middle frame to the first lower frame and attaching the second middle frame to the second lower frame. In one aspect, the frame moving system includes a base and a plurality of actuators extending in a typically vertical direction from the base. In one aspect, the actuators each include a telescoping hydraulic cylinder. In one aspect, the first upper frame and the second upper frame are arranged on opposing edges of a wellbore. In one aspect, the support is a platform floor. In one aspect, the support includes a back frame, a rear spreader frame, and a setback spreader frame.
The present disclosure also describes an apparatus including a support; a first upper frame and a second upper frame each attached to the support; and a plurality of actuators extending from a base in a vertical direction, the plurality of actuators located below the support and between the first upper frame and the second upper frame; wherein each of the actuators is extendable and retractable along a vertical axis; wherein each of the actuators is adapted to engage the support and raise or lower the support in the vertical direction upon the extension or retraction of each actuator; wherein the plurality of actuators are adapted to extend to a first height at which a first middle frame may be arranged below the first upper frame and a second middle frame may be arranged below the second upper frame; and wherein the plurality of actuators are adapted to retract to a second height at which the first middle frame may be attached to the first upper frame and the second middle frame may be attached to the second upper frame. In one aspect, the plurality of actuators are adapted to extend to a third height at which a first lower frame may be arranged below the first middle frame and a second lower frame may be arranged below the second middle frame; and wherein the plurality of actuators are adapted to retract to a fourth height at which the first lower frame may be attached to the first middle frame and the second lower frame may be attached to the second middle frame. In one aspect, the actuators each include a hydraulically telescoping cylinder. In one aspect, the support is a platform floor. In one aspect, the support includes a back frame, a rear spreader frame, and a setback spreader frame. In one aspect, the plurality of actuators are arranged relative to a wellbore site.
In several exemplary embodiments, the elements and teachings of the various illustrative exemplary embodiments may be combined in whole or in part in some or all of the illustrative exemplary embodiments. In addition, one or more of the elements and teachings of the various illustrative exemplary embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
Any spatial references such as, for example, “upper,” “lower,” “above,” “below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.
In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes and/or procedures may be merged into one or more steps, processes and/or procedures.
In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.
Although several exemplary embodiments have been described in detail above, the embodiments described are exemplary only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.
The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. §1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.
