Note: Descriptions are shown in the official language in which they were submitted.
CA 02553470 2008-10-02
APPARATUS FOR SLANT DRILLING
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rig which can efficiently and economically
drill
wells at virtually any angle, from nearly horizontal to vertical. More
particularly still, the
present invention relates to a rig which can efficiently and economically
drill wells,
1s including deviated or high angle wells, with less pipe stress and impact on
the
surrounding environment than conventional drilling rigs.
2. Description of the Prior Art
Many wells, such as oil andlor gas wells are drilled vertically into the
earth's
crust. ' However, it is frequently beneficial to drill wells at an angle from
vertical. Such
"deviated" wells are often drilled from a single surface location towards one
or more
subsurface targets which are situated some lateral distance away from said
surface
location. In many cases, such deviated wells are intentionally oriented to
penetrate one
or more subterranean formations at a desired angle from vertical.
Frequently, wells are drilled vertically at the earth's surface, and
thereafter
deviated in a different direction -- that is, a desired angle from vertical --
at some point
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downhole. In other situations, it is often desirable to drill a deviated well
at an angle
from vertical starting at or very near the earth's surface. Specialized slant
rigs have
been developed for such wells. Unlike standard drilling rigs which typically
have fixed
vertical derricks, such specialized slant rigs have derricks which can be
tilted from
s vertical. Most existing slant rigs can tilt from horizontal to approximately
30 degrees, or
from vertical to about 45 degrees. However, such existing rigs cannot slant at
virtually
any angle between 0 and 90 degrees - that is, from nearly horizontal to
vertical.
Such conventional slant rigs suffer from a number of shortcomings. Most
notably, such rigs do not have lifting, pulling or pushing capacity comparable
to
standard drilling rigs having stationary, vertical derricks. As a result, such
conventional
slant rigs are not able to drill deep wells, and/or wells that have a
significant lateral
component.
Thus, it is an object of the present invention to provide a rig that can drill
deviated wells at an angle from vertical. It is yet another object of the
present invention
1s to provide a rig having significant lifting capacity that can drill
deviated wells to depths
which are comparable to those drilled by standard larger capacity drilling
rigs.
SUMMARY OF THE INVENTION
The rig of the present invention can be used to drill, complete, re-complete,
work
over and/or plug and abandon many different types of wells, from vertical
wells to
deviated or horizontal wells. Although the slant rig of the present invention
is described
herein primarily in connection with the drilling of oil and gas wells and
related activities,
it is to be observed that the rig of the present invention can also be
beneficially utilized
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to drill water wells environmental monitoring wells and/or other wellbores, as
well as
directional holes for pipelines, utility lines and the like.
The present invention comprises a rig having a derrick which can tilt at
virtually
any angle from nearly horizontal to vertical. A device, commonly known as a
"top drive"
unit, can be selectively raised and lowered within such derrick. Said top
drive unit can
include upper slips for gripping the outer surface of a section of pipe, as
well as a power
swivel or similar device for rotating or spinning such pipe about its
longitudinal axis
when gripped within the slips of said top drive unit, a section of pipe can be
raised or
lowered within a derrick. Said top drive unit also permits communication of
fluid into
io the inner flow path of a section of pipe secured within said top drive
unit.
A jack apparatus is mounted within said derrick, ideally near the base of said
derrick. Although said jack apparatus can utilize any number of power sources,
in the
preferred embodiment of the present invention, said jack apparatus includes
one or
more hydraulic cylinders which can extend or collapse within said derrick.
Further, said
jack apparatus includes at least one set of slips for gripping the outer
surface of a
section of pipe, as well as means for spinning or rotating said pipe about its
longitudinal
axis while it is being held within said jack apparatus. In the preferred
embodiment, said
jack apparatus has tvio independent sets of slips and significantly greater
lifting
capacity than the top drive apparatus/derrick of the present invention. When
required
to hold, push, drill or pull weight -into a well, said jack apparatus can be
used either in
connection with, or in place of, the top drive unit which is mounted within
said derrick.
Further, pipe held within said jack apparatus can be rotated independent from
pipe held
within said top drive unit.
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In the preferred embodiment of the present invention, an automated pipe
handling apparatus is also provided which permits efficient transfer of pipe
sections
from said derrick (and jack apparatus) to a truck, pipe rack or other storage
facility. As
a result of such automated pipe handling apparatus, the labor requirement
associated
with loading and unloading pipe is substantially less than labor requirements
associated
with conventional drilling rigs. Safety is also greatly improved as a result
of such
automated pipe handling apparatus since it is generally not necessary to
position
personnel within the derrick. Additionally, less personnel are required on the
rig floor
compared to standard ri:gs.
The slant rig of the present invention can be trailer-mounted for easy
transportation to and from well sites using standard trucks. Similarly, the
various
components of said rig including, without limitation, mud tanks, pumps,
control
equipment and crew quarters, can also be skid, track truck-mounted. As a
result, said
components can be efficiently and economically transported to and from well
sites.
Said components can also be quickly mobilized at a desired drilling location,
and
thereafter demobilized upon completion of operations.
In certain situations, it may also be beneficial to mount the slant rig of the
present invention (regardless of whether or not said rig and related
components are
skid, track or truck-mounted) on a hovercraft or other similar device. Because
the slant
rig of the present invention has a relatively small "footprint", it has space
requirements
that are significantly less than those of conventional drilling rigs.
Hovercrafts, which are
capable of traveling on an air cushion above the surface of land or water,
permit the
slant rig of the present invention to access areas, including environmentally
sensitive
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areas, without significant disturbance to the ground or mud-line. Such impact
is reduced
both while the rig of the present invention is working on location, as well as
during the
period that it is being transported to and from such location.
According to one aspect of the present invention there is provided a drilling
rig
comprising: a. a derrick having a length, wherein the derrick can be tilted at
any angle
between 0 and 90 degrees from vertical; b. a top drive unit slidably mounted
to the
derrick; and c. a jack disposed at the base of the derrick having a stroke
parallel to the
longitudinal axis of the derrick, wherein the jack can support, push and pull
weight
independently from the derrick and top drive, and further comprises: i. means
for
connecting the jack directly to a section of pipe; and ii. means for rotating
a section of
pipe connected to the jack.
According to a further aspect of the present invention there is provided a
drilling
rig comprising: a. a base; b. a derrick having a top, a bottom and a length,
wherein the
bottom of the derrick is pivotally mounted to the base, and the derrick pivots
about a
substantially horizontal pivot axis; c. a top drive unit movably disposed
along the length
of the derrick, the top drive unit comprising: means for connecting the top
drive unit to a
section of pipe; means for communicating fluid in and out of a section of pipe
connected
to the top drive unit; and a powered rotary for rotating the section of pipe
connected to
the top drive unit; and d. a jack, disposed near the bottom of the derrick,
wherein the
jack can support, push and pull weight independently from the derrick and top
drive, the
jack comprising: i. at least one slip assembly for directly gripping a section
of pipe; and ii.
at least one powered rotary for rotating a section of pipe disposed within the
at least one
slip assembly.
According to another aspect of the present invention there is provided a
drilling
rig comprising: a. a base; b. extendable derrick having a top, a bottom and an
adjustable
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length, wherein the bottom of the derrick is pivotally mounted to the base and
the
derrick pivots about a substantially horizontal pivot axis; c. at least one
hydraulic cylinder
having a first end and a second end, wherein the first end of the at least one
hydraulic
cylinder is attached to the base and the second end of the at least one
hydraulic cylinder
is attached to the derrick; d. a top drive unit movably disposed along the
length of the
derrick, the top drive unit comprising: means for connecting the top drive
unit to a section
of pipe; means for communicating fluid in and out of a section of pipe
connected to the
top drive unit; and a powered rotary for rotating the section of pipe; e. a
jack, disposed
near the base, comprising: i. a substantially stationary base; ii. a traveling
member; iii. a
plurality of hydraulic cylinders connecting the traveling member to the
substantially
stationary base; iv a first powered rotary disposed on the traveling member;
v. at least
one slip assembly connected to the first powered rotary; vi. a second powered
rotary
disposed on the substantially stationary base; and vii. at least one slip
assembly
connected to the second powered rotary.
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BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 depicts a side view of a trailer-mounted slant rig of the present
invention with the derrick in a fully tilted, horizontal position.
FIGURE 2 depicts an overhead view of a derrick of the present invention in the
s fully tilted, horizontal position (not including pipe handling apparatus and
top drive unit).
FIGURE 3 depicts a side view of a trailer-mounted slant rig of the present
invention with the derrick in a vertical position.
FIGURE 4 depicts an end view of a trailer-mounted slant rig of the present
invention with the derrick in a vertical position.
FIGURE 5 depicts a side view of a trailer-mounted slant rig of the present
invention with the derrick at an angle between horizontal and vertical.
FIGURE 6 depicts a side view of an automated pipe handling apparatus of the
present invention.
FIGURE 7 depicts an overhead perspective view of the automated pipe handling
apparatus of the present invention.
FIGURE 8 depicts a side view of a top drive apparatus of the present
invention.
FIGURE 9 depicts a side view of a jack apparatus of the present invention.
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DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Referring to the drawings, FIGURE 1 depicts a side view of slant rig 10 of the
present invention. In the preferred embodiment of the present invention, slant
rig 10 is
mounted on trailer 11. Trailer 11 can in turn be attached to, and pulled by,
tractor 12.
s In this configuration, slant rig 10 can be easily and conveniently
transported to and from
desired locations. Derrick 20 is mounted on trailer 11. Adjustable trailer
pedestals 13
can be used to provide additional support and stability to trailer 11,
especially when said
trailer 11 is rigged up at a desired work site.
In the preferred embodiment, derrick 20 can be tilted about a horizontal pivot
axis passing through pin 14. During transportation of slant rig 10, derrick 20
is
frequently in a collapsed or horizontal position on trailer 11. Hydraulic
cylinders 15 can
be used to lift derrick 20 and thereby tilt said derrick about pivot pin 14.
More
specifically, hydraulic cylinders 15 can be extended or collapsed to position
derrick 20
at a desired angle between 0 and 90 degrees, that is, between horizontal and
vertical
orientation. Similarly, adjustable support 16 is provided to give additional
support to
derrick 20 when it is raised to a desired angle from a horizontal position.
Winch 17 can
also be used, in connection with pulley mechanisms to raise and lower
equipment
within derrick 20. Hydraulic power-pack 18 is mounted on trailer 11 to provide
power to
the components of slant rig 10.
Automated pipe handling apparatus 60 of the present invention is mounted to
derrick 20. Adjustable work platform 19 is also mounted to derrick 20 near the
base of
said derrick 20. In the preferred embodiment, automated pipe handling
apparatus 60 is
slidably mounted to derrick 20, and adjustable work platform 19 provides a
substantially
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horizontal work deck or rig floor which can be used during drilling
operations. Said
adjustable work platform 19 can be set in a horizontal orientation regardless
of the
angle of derrick 20. Although not specifically depicted in the drawings, it is
to be
observed that slant rig 10 of the present invention will frequently include
other
equipment or components that are usual and customary on conventional drilling
rigs.
For example, slant rig 10 of the present invention may include mud tanks, mud
pumps,
shale shakers, control equipment, crew quarters, and the like. In the
preferred
embodiment, such components are also ideally modular in construction and
trailer-
mounted for easy transportation, as well as mobilization and demobilization at
a well
site.
FIGURE 2 depicts an overhead view of derrick 20 of the present invention in a
horizontal orientation, such as during transportation to or from a well site.
Although
derrick 20 can be constructed in any number of different configurations, in
the preferred
embodiment derrick 20 comprises parallel rails 21 and 22. Cross members 23
provide
1s added strength to derrick 20. In the configuration depicted in FIGURE 2,
work platform
19 is collapsed against derrick 20 while slant rig 10 of the present invention
is being
transported. Similarly, automated pipe handling apparatus 60 of the present
invention
is also collapsed against derrick 20 in FIGURE 2. In the preferred embodiment
of the
present invention, derrick 20 can be telescopically extended to increase the
overall
length of said derrick. Thus, although derrick 20 of the present invention is
depicted in
a collapsed or retracted configuration, it is to observed that derrick 20 can
also be
telescopically extended to increase the overall length of derrick 20.
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FIGURE 3 depicts a side view of slant rig 10 of the present invention in a
fully
rigged-up configuration over well 30. During mobilization, trailer 11 is
transported to,
and positioned at, a desired work location. Derrick 20 of the present
invention is
oriented in an upright vertical position over well 30 using hydraulic
cylinders 15. When
s derrick 20 is in such an upright vertical position, hydraulic cylinders 15
are in a fully
extended position. Adjustable support member 16 provides added support to
derrick 20
and serves to maintain its stability.
Still referring to FIGURE 3, derrick 20 of the present invention is
telescopically
extended to increase its overall length. Further, work platform 19 is deployed
to provide
a substantially horizontal work platform or rig floor for use in connection
with slant rig
10. Said work platform 19 can be used to provide a platform for rig personnel
to work
during drilling operations. Top drive apparatus 80 is slidably mounted within
derrick 20,
while jack apparatus 90 is mounted near the base of derrick 20 in general
proximity to
well 30. Automated pipe handling apparatus 60 is mounted within derrick 20,
although
t$ said jack apparatus is partially obscured from view in FIGURE 3.
FIGURE 4 depicts an end view of slant rig 10 of the present invention in the
same basic configuration shown FIGURE 3. Derrick 20 having parallel rails 21
and 22,
as well as cross members 23, is in a fully upright, vertical position.
Further, derrick 20 is
telescopically extended to a desired length. In most cases, during operation
such
length is greater than the length of derrick 20 when said derrick is
collapsed, such as
during transportation. Although generally obstructed from clear view in FIGURE
3,
FIGURE 4 depicts automated pipe handling apparatus 60, top-drive apparatus 80
and
jack apparatus 90 installed within derrick 20.
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FIGURE 5 depicts a side view of slant rig 10 of the present invention in a
fully
rigged-up configuration. During mobilization, trailer 11 is transported and
positioned at
a desired work location over well 30. Derrick 20 of the present invention is
oriented in a
slant or angled position; said orientation of derrick 20 is at an acute angle,
wherein said
s derrick 20 is at a desired angle between horizontal and vertical. Said
derrick 20 is
oriented at the desired angle using hydraulic cylinders 15. When derrick 20 is
in the
desired position, adjustabie support member 16 is used to provide added
support to
derrick 20 and serves to maintain the stability of said derrick 20. Work
platform 19 is
deployed to provide a substantially horizontal work platform or rig floor for
slant rig 10
ia even when derrick 20 is oriented at a slant as in FIGURE 5. Said work
platform 19 can
be used to provide a platform for rig personnel to work during drilling
operations.
FIGURE 6 depicts a side view of automated pipe handling apparatus 60 of the
present invention. Automated pipe handling apparatus of the present invention
includes bracket apparatus 61. In the preferred embodiment, said bracket
apparatus
15 61 is slidably mounted to derrick 20 of the present invention. In the
preferred
embodiment, bracket apparatus 61 can slide along rail 21 of derrick 20, or a
track
mounted thereto, and travel along a portion of the length of said derrick 20.
Mounting plate 62 is pivotally attached to bracket apparatus 61 via lower
swivel
apparatus 63 and upper pivot pin 64. Said mounting plate 62 can pivot relative
to
20 bracket apparatus 61 about a pivot axis passing through said lower swivel
apparatus
63 and upper pivot pin 64. Cantilever arm 65 extends outward from Mounting
plate 62.
Pipe gripper apparatus 66 is attached to the distal end of cantilever arm 65.
Bracing
member 67 extends from mounting plate 62 to pipe gripper apparatus 66, and
provides
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structural reinforcement to cantilever arm 65 and pipe gripper apparatus 66.
Pipe
gripper apparatus 66 includes post 70, as well as upper pipe gripper 68
mounted to the
upper end of post 70, and lower pipe gripper 69 mounted to the lower end of
post 70.
Referring to FIGURE 7, upper pipe gripper 68 is connected to the upper extent
s of post 70, while lower pipe gripper 69 is connected to the lower extent of
post 70.
Upper pipe gripper 68 comprises opposing arcuate jaws 68a and 68b. Similarly,
lower
pipe gripper 69 comprises opposing arcuate jaws 69a and 69b. Post 70 is
mounted to
cantilever arm 65 via swivel apparatus 72. Said post 70 can rotate about an
axis
passing through cantilever arm 65. Cradle 71 is mounted to post 70 and
provides a
base for receiving a section of pipe.
In operation, automated pipe handling apparatus 60 of the present invention
can
be used to transfer pipe into derrick 20 from a waiting truck, pipe rack or
other pipe
storage device. Simi4arly, automated pipe handling apparatus 60 can be used to
transfer pipe out of said derrick 20, and load such pipe into a waiting truck,
pipe rack or
other pipe storage device. Pipe handling apparatus 60 can be positioned along
the
length of derrick 20 using traveling bracket apparatus 61.
FIGURE 8 depicts side view of top drive apparatus 80 of the present invention.
Top drive apparatus 80 comprises swivel mechanism 81, and fluid connection
line 82.
Said top drive apparatus can be raised and lowered within derrick 20 via
slidable
mounting brackets 83 and 84. Internal slips (not shown in FIGURE 8) allow top
drive
assembly 80 to grip the outer surface of a section of pipe. When a section of
pipe is
connected to top drive assembly 80 within derrick 20 of the present invention,
said pipe
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can be rotated using swivel mechanism 81, while fluid can flow into and out of
such a
section of pipe via fluid connection line 82.
Referring to FIGURE 9, jack apparatus 90 is mounted within derrick 20, ideally
near the base of said derrick 20. In the preferred embodiment, said jack
apparatus is
mounted on a wellhead, or directly on the ground. Although said jack apparatus
can
utilize any number of power sources, in the preferred embodiment of the
present
invention, said jack apparatus 90 includes a plurality hydraulic cylinders 91,
which can
be extended or collapsed within derrick 20. Further, said jack apparatus 90
includes at
least one set of slips 92 for gripping the outer surface of a section of pipe,
as well as
io power swivel 93 for spinning or rotating said pipe about its longitudinal
axis while it is
being held within said jack apparatus 90. In the preferred embodiment, said
jack
apparatus 90 has significantly greater lifting capacity than the top drive
apparatus 80
and/or derrick 20 of the present invention. As a result, when required to
hold, push, drill
or pull weight into or out of a well, said jack apparatus 90 can be used
either in
is connection with, or in place of, said top drive unit which is mounted
within said derrick.
Because said jack apparatus 90 is not mounted directly to derrick 20, it is
capable of lifting, pulling, pushing or otherwise manipulating pipe
independently from
derrick 20. In other words, the lifting, pulling, pushing or other strength
capacity of said
jack apparatus 90 is not limited by the capacity of said derrick 20 or top
drive apparatus
20 80 mounted within said derrick. As such, said jack apparatus has
significantly greater
strength capacity than a slant rig which is not equipped with such jack
apparatus.
Because both top drive unit 80 and jack apparatus 90 are capable of gripping
pipe and rotating such pipe, it is possible to simultaneously drill one size
pipe
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concentrically within another size pipe. As a result the slant rig 10 of the
present
invention is far more versatile than conventional rigs. For example, slant rig
10 of the
present invention can be used to simultaneously drill well casing using jack
apparatus
90, and tubing or drill pipe concentually through such casing using top drive
unit 80.
As set forth above, in certain applications it may also be beneficial to mount
slant
rig 10 of the present invention (regardless of whether or not said rig and
related
components are skid, track or truck-mounted) on a hovercraft or other similar
device.
Because slant rig 10 of the present invention has a relatively small
"footprint", it has
space requirements that are significantly less than those of conventional
drilling rigs.
Hovercrafts, which are capable of traveling on an air cushion above the
surface of land
or water, permit the slant rig of the present invention to access areas,
including
environmentally sensitive areas, without significant disturbance to the ground
or mud-
line. Such impact is reduced both while the rig of the present invention is
working on
location, as well as during the period that it is being transported to and
from such
location.
The above disclosed invention has a number of particular features which should
preferably be employed in combination, although each is useful separately
without
departure from the scope of the invention. While the preferred embodiment of
the
present invention is shown and described herein, it will be understood that
the invention
may be embodied otherwise than herein specifically illustrated or described,
and that
certain changes in form and arrangement of parts and the specific manner of
practicing
the invention may be made within the underlying idea or principles of the
invention
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