Note: Descriptions are shown in the official language in which they were submitted.
CA 02595666 2007-07-25
MODULAR COILED TUBING AND SECTIONAL PIPE DRILLING RIG
Field Of The Invention
This invention relates to a drilling rig of the type used in drilling and
servicing
boreholes, and more particularly, to one formed of separate units or modules,
capable
of being readily transported and then assembled for use with coiled tubing or
threaded pipe sections.
Background Of The Invention
The use of the coiled tubing technique in forming and servicing well
boreholes has gained wide spread acceptance in the last decade due to the
convenience and speed of using a continuous length of tubing from a reel as
opposed
to the amount of labour and time required in using the conventional method of
joining and disassembling of sections of lengths of threaded pipe. Initially,
it was a
common practice to mount a reel of the coiled tubing on a transport deck also
canying a mast or boom supporting an injector which is supported over the well
head, although prior art exists wherein the injector was supported separate
from the
reel carrier. In any event, the coiled tubing process has limitations under
certain
drilling conditions, and as a result various equipment and techniques have
developed
for being able to switch back and forth between the two different processes in
the
drilling and servicing of a single well. Various techniques have developed for
combining into a single well operation the necessary components to allow quick
and
effective changes between the two processes, and this together with the
increased
tubular size has resulted in the need to transport extremely heavy equipment
to and
from the drilling site. Even with the provision of the necessary equipment for
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providing both types of operations at the site at the same time, much of the
equipment
design which followed utilized a single transport unit. Not only does the
weight and
size result in complicated moving from one drill site to another in the oil
field, but the
weight regulations on public roadways set strict restrictions in size and
weight as to
what can be taken to or removed from the oil field. It had become known, that
there
is added convenience in providing at least the reel of coiled tubing on a
separate
transport, as shown in applicant's Canadian Patent Application No. 2,529,921,
filed,
December 13, 2005, Allan J. Pleskie. Nevertheless, again in view of the added
size
and weight of the overall drilling rig, there has existed a need for providing
a more
flexible and convenient method of transport and set-up at the drilling site.
Summary Of The Invention
It is an object of the present invention to provide an overall drill rig
formed of
readily separable units or modules each of which is of a weight and dimension
which
can be more conveniently moved from site to site each with more reasonable
weight
and within set requirements, and yet also be readily assembled and
disassembled on
site.
According to the present invention there is provided a drilling rig of the
type
for forming and servicing boreholes, and includes at least three separably
transportable modules, including a substructure component, a mast component
and an
injection component. A first transportable module forming the substructure
component includes a framework base structure having a ground engaging lower
portion for supporting the rig. The framework base includes a well head area
with a
vertical axis therein adjacent one end of the framework base for alignment
with the
borehole, and a bed area extending to an opposite end of the framework base.
The
mast component of the rig includes a base portion and a mast framework having
a
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longitudinal central axis and being pivotally attached to the base portion for
movement between a lowered position and a raised operative position. The base
portion of the second module is shaped for receprion in the bed of the
substructure
component of the first module so as to position the second modular component
for
alignment of the mast framework in the raised position with the axis of the
well area
of the first substructure component. The base portion of the mast component
defines
an upper support area. The injector component includes an injector carrier and
a
tubing injector having attachment means for connection to the mast framework,
the
injector carrier being adapted to be positioned on the upper supporting area
of the
base portion of the mast component and supporting the injector in a locarion
for
connection of the tubing injector to the mast framework when the mast
framework is
in a loading lowered position so as to allow loading of the tubing injector in
relation
to the mast.
There maybe further provided a fourth module which includes a transport
component for carrying a coiled tube holding reel for placement juxtapose the
substructure component and mast component when assembled for supplying to and
receiving from the injector component the coiled tubing.
Yet an independent transportable module may be provided which forms a
power pack component for positioning juxtapose the second and fourth module
for
supplying power services thereto.
Brief Description Of The Drawings
In the accompanying drawings, which show one preferred embodiment of the
invention, by way of example:
Figure 1 shows a side view of a first module of the invention which is a
separate component in the form of a substructure;
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Figure 2 is a top view of the substructure of Figure 1;
Figure 3 is an end view of the substructure of Figures 1 and 2, as seen from
the right hand end;
Figure 4 is a side view of another component unit which is a portable power
pack for providing power to the rig of the present invention in operation;
Figure 5 is a side view of another component of the invention which is formed
by drawworks/mast structure, hereafter referred to as the mast component,
carried on
its own framework and in a transport mode;
Figure 6 is a top view of the structure shown in Figure 5;
Figure 7 is a side view of the mast component of Figure 5 and 6 as combined
with and mounted within the substructure component of Figures 1- 3;
Figure 8 is a top view of the combined structure of Figure 7;
Figure 9 is an end view of the combined structure as seen from the right hand
end of Figures 7 and 8;
Figure 10 is a side view of the combined structure as seen in Figure 6, with
the
mast in a raised and extended condition wherein the top drive may be used in
manipulating threaded pipe sections during certain operations in forming the
borehole;
Figure 11 is a end view of the structure in the mode of Figure 10 as seen from
the right hand end of Figure 10;
Figure 12 is a perspective view of an injection unit, hereinafter referred to
as
the injector, as utilized in the coiled tubing processing work within the
borehole;
Figure 13 is a side view of another module or component of the present
invention which includes the injector unit of Figure 12 carried on its
loading/unloading mechanism within its own transport framework;
Figure 14 is a top view of the separate component as seen in Figure 13, of the
invention.
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Figure 15 is an end view of the component of Figures 12 and 13 as seen from
the right hand end of Figures 13 and 14;
Figure 16 is a side view of the drilling rig of the present invention with the
mast in a raised working mode and wherein the injector component of Figures 13
to
15 is mounted on the frame structure of the mast component.
Figure 17 is a side view of the structure as in Figure 16, and wherein the
mast
has been lowered to a position for the mounting of the injector unit of Figure
12 as
carried within the injector component of Figures 13 and 14.
Figure 18 is a perspective view of the overall structure of the components of
the present invention, less the reel storage component and power package,
showing
the relative positioning of the mast and injection component.
Figure 19 is a side view like Figure 17, but with the loading/unloading unit
extended to an injector loading position
Figure 20 is a side view of the components of Figure 18, but in a position
after
the mast has been raised to its operation position with the injector loaded
into the
mast;
Figure 21 is an end view of the overall structure of Figure 18 as seen from
the
right hand end; and
Figure 22 is a side view of a complete final set up of the apparatus,
including
the reel storage component and showing the relative position of the injector
unit and
the mast after the fmal operation of moving the injection unit into its fmal
operating
mode.
Figure 23 is an end view of the apparatus of Figure 22, as seen from the right
hand side showing the apparatus of the present invention in a coil tubing
working
mode.
Figure 24 is an enlarged, perspective view of a portion of the mast containing
the injector, and showing a locking and positioning mechanism within the mast.
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Detailed Description
Referring first briefly to Figure 22, there is shown a complete set up at a
drilling site of rig 30 of the present invention in an operating mode and
incorporating
the present invention. The rig 30 includes an overall substructure or base
component
31 on which there is mounted a drawwork/mast module, hereinafter referred to
as a
mast component 52. On the mast component 52 there is mounted an injector
carrier
32. The mast component 52 includes an upright mast 33 which is provided with a
top drive apparatus 34 and supports an injector component 75 during a coiled
tubing
operation. A separate module or transport component 36 carries a reel 37 which
furthers supplies coiled tubing 38 during a drilling operation, or receives
the coiled
tubing during its withdrawal from a well.
In an operatively assembled form in Figure 1, there is shown the first module
or base component 31 which is in the form of a completely separable
substructure 40.
This component is movable to and from a drill site by a carrier such as a
highway
transport. Examples of its overall dimensions may be about 50 feet long, 14
feet
wide and 14 feet high at its area of maximum height. As can be noted from
Figure 2,
the base component 31 in plan view has an overall outside rectangular shape
and is
constructed basically of a steel framework. One end 41, as seen at the left
hand end
in Figure 1, has a greater height in relation to an opposite lower end portion
42, the
latter of which is adapted to receive the drawwork/mast module shown in Figure
5
and 6, and hereinafter referred to as the mast component 52. Located in the
raised
end portion of the substructure 40 is a well area 43, which in operation is
located
over the borehole centre. The outermost longitudinal upright sides 44,44 of
the
framework are supported at lower ends on longitudinally extending runners
45,45
which effectively provide a skid for the base of the overall base component
31. A
platform 46 area is provided between the sides 44,44 at the raised portion
about the
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well area 43. Formed longitudinally between side walkways 47,47 which extend
the
length of the lower end portion 42 is a lower channel area 48 forming an
elongated
bed. The channel area or bed 48 is shaped to receive the mast component 52
when
the mast component and base component 31 are assembled on site. The bed area
42
is open at the outer end of lower end portion 42, and longitudinally extending
support
rails 49,49 are provided at the bottom of the channel area 48 to carry a base
53
(Figure 5) of the mast component 52. An elongated roller 50 is provided
between
rails 49,49 at their outer end to assist in initial entry of the mast
component 52 during
assembly of the mast component 52 into the substructure 40. As will become
more
apparent below, during operation of the rig 30, the mast component 52 has its
lower
portion nested with the lower channel area 48 as the rig is assembled for
operation on
site. Along outside edges of the lower end portion of the substructure 40,
hand rails
51,51 are provided as well as stair structures 54 which are properly moved
into
position when the mast component is installed. Hand rails 58 are also provided
at the
edges of the raised end portion 41 as well but are adapted to fold down to a
flat,
horizontal position for shipping.
Figure 4 illustrates another separate module, which may be termed a power
pack 55, and includes a platform 56 mounted on skids 57, and on which are
carried a
prime mover, for driving one or more components, such as an electrical
generator, an
air compressor and associated tank, a hydraulic pump and associated reservoir,
and
the like. While the base component 31 or mast component 52 may be provided on
or
within their substructures an area to contain the power pack 55, it may be
delivered
to the site separately and possibly located at a distance from the overall rig
30 setup.
Referring now to Figures 5 and 6 for a more complete understanding of the
completely separate module forming the mast component 52, it may be noted its
base
53 has an integral raised framework section 61 at one end thereof and by way
of a
pivot connection 60, there is connection to this raised framework 61 a lower
end 62
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of a mast framework 63. As is apparent in Figure 5, the free end of the base
53 does
not extend horizontally to the same extent as the collapsed mast framework 63.
In its
shipping state, as illustrated in Figures 5 and 6, the overall length of the
mast
component may be in the order of 56 feet. When assembled in the channel area
48 of
the base component 31, as shown for example in Figure 7, the free end of the
base 53
projects outwardly of the end of the base component 31. The structure forming
the
base 53 of the mast component 52 is also designed so as to provide a skid
structure
for the mast component 52. It is to be noted that toward the outer end of
lower frame
structure 65 of the mast framework 63 there is attached thereto a pair of
perpendicular projecting legs 64 which are of a length to rest on the base 53
of the
mast component 52 when the mast framework is in its completely lowered
horizontal
position so as to transfer the weight of the mast 33 at this point directly to
the base
during transport.
The mast framework 63 has a telescoping form so that in an extended
condition, which is more apparent in Figures 10 and 11, it has a significantly
greater
height than its length when in the lowered form of Figures 6 and 7, the total
mast
structure including telescopically joined lower framework 65 and an upper
framework 66. When in an operating condition the upper framework 66 is
elevated
relative to the lower framework 65 by drawworks with lifting cables (not
shown) to
provide the higher mast particularly for use when the rig is being used for
drilling
with threaded pipe sections. Contained within the mast is a top drive
apparatus 70
for use with the threaded pipe sections. The top drive apparatus 70 can be run
substantially the full height of the mast framework in a continuous aligned
track
system within the two sections of the extended mast framework 63 by way of
cables
68 which pass over the sheaves 67 at the top of the upper frame structure 66.
Housed
in the raised framework 61 of the base 53 are motor driven winches 69 for
controlling
the winding in and paying out of cables 68.
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Expandible piston and cylinder type motors 71 are pivotally connected at
lower ends to the base 31 of the mast component 52 and at upper ends to the
lower
frame structure 65 of the mast framework 63. Accordingly, on expansion of the
motors 71, the mast framework can be raised by pivoting about pivot connection
60
from a horizontal position to its upright position. After this operation, the
upper
structure 66 of the mast framework is raised to its elevated position where it
remains
regardless of whether the top drive apparatus 70 is being used or
alternatively the
injector 35 has been inserted into its elevated operation position within the
mast 33 as
further described below.
As shown in the Figures 5 and 6, the base 53 of the mast component 52
provides an upper surface 59 which is readily accessible within the combined
structure provided by the substructure component 40 and the mast component 52
when the mast is in a raised condition. As will become more obvious below this
surface 59 is below the open area 74 of the mast framework 63 when the mast is
lowered while in its extended condition. This upper surface 59 thus provides
an
upper support area for injector carrier 32, for reasons which will be
hereinafter
described.
In Figures 7, 8 and 9, the drilling rig is shown at the stage of the mast
component 52 being fully assembled into the base component 31, and with other
auxiliary parts, such as the stairs 54, hand rails 58, etc. being moved into
their
working positions. As is apparent from Figures 7 and 8, when the mast
component
52 is fully nestled within its channel area 48 of the base component 31, the
end of the
pivotal connection 60 is located partially within the higher end portion 41 of
the base
component 31, and is positioned so that as the mast is raised by motors 71,
the central
longitudinal work axis of the mast is moved to a position aligned with the
well centre
area 43 in the base component, which is located vertically above the borehole,
as can
be seen in Figures 10 and 11.
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In the vertical position of the mast 33, as shown in Figures 10 and 11,
without
the injector 35 having been attached in the open area indicated at 74 within
the mast
framework 63, the rig is capable of operating with threaded pipe sections by
using
the top drive apparatus 34. As previously indicated, the top drive apparatus
34 is
capable of travelling in aligned tracks within the lower and upper mast
structure of
sections 65,66. Thus, the rig is then totally functional in the usual manner
as a rigid
pipe drilling apparatus area with the top drive apparatus 34 being aligned
with the
well centre area of the base component 31. As previously indicated, the
vertical
positioning of the top drive apparatus 34 is determined by the operation of
the motor
driven winch means 69, (Figure 5) by way of cables 68.
There is shown in Figure 12, the injector 35 which is optionally loaded into
the open area 74 at the mast, once the top drive has been raised to a position
above
the open area 74, as shown, for example, in Figure 11. The position of the top
drive
shown in Figure 11 represents one which is used when it is desirable to
commence
the use of coiled tubing in the drilling or servicing operations in the
borehole. As can
be seen in Figure 12, the injector 35 per se is provided with a base member 76
and a
head member 77 which are shaped for reception in the open area 74 within the
mast
framework 63. Located between the base member 76 and the head member 77 is the
injector body 78 which includes two sets of driven gripper chains (not shown)
which
engage the coiled tubing and, depending on the direction of drive of the
chains, the
chains either push the tubing down into the well or pulls it upwardly out of
the well
when using the coiled tubing process. As may be seen in Figure 15, the base
member
has a central opening 80 through which the tubing is pulled or pushed,
depending on
the operation in process. In operation, the opening 80 is in alignment with
the well
centre area 43 of the base component. In addition to the securement of the
injector
78 between the base member 76 and head member 77, a framework 79 is provided
outside of the injector body 78 and is joined at lower and upper ends to the
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CA 02595666 2007-07-25
member 76 and head members 77, respectively.
As is apparent in Figure 12, the base member 76 of the injector 35 is provided
with a pair of rigid locating lugs 84,84 at opposite sides thereof which
function as
stops to locate the injector 35 as it is being raised into loading position
within the
open area 74 within the mast framework 63. The base member 76 also includes an
intemal hydraulic mechanism for extending and retracting cylindrically shaped
lock
members 72, 72 which secure the base member 76 within the mast 33 when
extended.
The head member also has a pair of rectangular shaped lock members 73,73 which
are hydraulically extendable and retractable from opposite sides thereof. The
action
of the lock members is further described below.
Secured to the head member 77 of the injector 35 is a gooseneck 81, which is
of the type formed by two sections, a base portion 82 which is affixed
relative to the
head member 77 of the injector 35, and an outer end portion 83 which is hinged
to an
outer end of the base portion 82 so as to fold under when it is not in use and
thereby
occupy less space. When in use, the gooseneck 81 provides a track of a
smoothly
formed curvature in which the coiled tubing passes when travelling from its
storage
reel 37 to the injector 35, or in the opposite direction when the tubing is
being
withdrawn from the well and returned to the reel.
Turning now to Figures 13 to 15, there is shown a separately transportable
module, in the form of what is termed hereinafter the injector component 75
consisting of the above described injector 35 mounted on the injector carrier
32. As
indicated above also, this injector component is adapted to be accurately
located on
upper surface 59 provided on top of the base 53 of the mast component 52, once
the
mast 33 has been raised to an upright position. As will be described further
below,
when the mast 33 is then subsequently lowered, the open area 74 of the mast
partly
encompasses the injector 35 as it rests on the support mechanism 86 of the
injector
carrier 32 of the injector component 75.
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The injector carrier 32 includes a base 85, again in the form of a platform,
which provides a skid for this transport component so as to enhance its
movement on
the ground on its transporter or in placement on the platform or upper surface
59 on
the base of the mast component 52. The support mechanism 86 is affixed to the
top
of the base 85 and has an upper injector engagement member 87 which carries
the
injector 35 in a completely horizontal position. There is provided, however,
between
the member 87 and the base 85, a lift means 88 shown in the form of a scissor
mechanism, which may be actuated by a screw mechanism, hydraulic cylinder, or
the
like, to raise the injector 35. The lift means 88 is shown in Figure 19 in a
lift
position. Mounted on either side of the base 85 are mast support posts 90,90
which
extend upward and laterally outward and provide upper end surfaces 91,91 which
engage the fra.mework of the mast 33 as it is lowered to its slightly
inclined, injector
load position for pick-up or delivery of the injector 35. Thus, these posts
90,90 take
the weight of the mast 33 when it reaches its inclined pick-up position, and
supports
the weight of the mast and accurately ensures its position as the injector 35
is loaded
into or removed from its nested position in the open area 74 in the mast.
Turning now to Figure 16, which shows the rig ready to be prepared for
commencing a coiled tubing loading operation, the mast 33 being in its
vertical
operative position with the top drive apparatus 34 stored in a raised position
in the
upper frame structure 66 of the mast 33, well above the open area 74 of the
lower
frame structure 65 of the mast. The injector component 75 is mounted on the
upper
surface 59 of the base 53 of the mast component 52.
Prior to the injector 35 being lifted, the additional module in the form of
the
transport component 36 carrying the coiled tubing holding reel 37 is
positioned in
line with the assembled injector component 75 as mounted on platform 56 and
shown
in Figure 22. This Figure includes the transport unit 36 on which the coiled
tubing
reel 37 is mounted. It may be noted that a crane 96 having an extendable boom
92 is
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mounted rearwardly of the ree137 on the transport unit 36, this boom being
utilized
in the stabbing of the tubing into the injector prior to the injector being
raised into its
operative position. Normally a short length of tubing (not shown) is left in
the
injector 35 during transport. A tubing snake (not shown) is then attached to
the top
end of that length of tubing. The crane 96 which holds the free end of the
tubing on
the reel is then extended to pull that free end from the reel to the gooseneck
where it
is attached to the snake. Then by activating the injector momentarily while
the free
end is released by the crane, the coil from the ree137 is pulled by the snake
into the
injector, so as to allow the removal of the snake and short piece of tubing
which have
been pushed through opening 80 in the bottom end of the injector 35. A reverse
procedure is utilized after terminating of the coiled tubing drilling process
to ready
the equipment for transport so that the short piece of tubing is returned to
the injector
and the continuous length of tubing is returned entirely to the transport unit
36.
However, returning to the preparation for switching from a threaded tubular
operation to a coiled tubing operation, once the outer or free end 93 of the
tubing on
the reel 37 is in place within the injector 35 which is still positioned on
the lift means
88 of the support mechanism 85, the cylinders 71 (Figure 16) are then
retracted to
lower the still extended mast 33 to the lowered, inclined or angled position
wherein
the mast 33 engages the tops 91,91 of the support posts 90,91. With such
engagement there is established the correct position of the opening area 74 in
relation
to the partially encompassed injector 35. The lift means 88 of the support
mechanism 86 in the injector component is then activated to move the injector
33
from the position shown in Figure 17 to that shown in Figure 18 or Figure 19.
When
positioned initially in the open area 74 of the mast, the axis of the injector
35 is still
horizontally disposed, and thus at an angle relative to the central axis of
the slightly
inclined mast. When positioned in this manner the hydraulics within the base
member 76 and head member 77 of the injector 33 are activated to cause lock
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members 72 and 73 to move to an active position in which they project from
opposite
sides of the base member 76 and head member 77, respectively.
The lock members 72,72 in the base member 76, which are of circular cross
section, are positioned when supported by the support mechanism 86 so as to
project
into circular openings in a frame member 95 at opposite sides of the mast as
best
indicated in Figures 18 and 19. The lock members 73,73 when projected from the
head member with the injector in its horizontal position relative to an angle
of section
of the mast extend in front of locking pads 97,97, one of which is shown in
Figure
24. Each lock pad is integral with a piston rod of a hydraulic piston and
cylinder
type motor 98, the outer end of each such cylinder of being supported by the
framework 63 of the mast.
As the motors 98 remains in a retracted condition as the piston and cylinder
motors 71 are activated to commence raising of the mast 33 from its inclined
injector
loading position, the axis of the injector 35 remains at an angle relative to
the central
axis of the mast. In order to prevent damaging of the coiled tubing held in
the
injector, the mast is continued to be elevated towards its vertical working
position,
with the injector remaini.ng at the above described angle, usually until the
mast at
least approaches its entirely upright (Figures 20 and 21). In order to place
the
injector 35 in its working position relative to the mast, i.e., with the axis
of the
injector and that of the mast coinciding, the motors 98 are activated to
extend their
length whereby the pads 97 push the extended lock members 73,73 and thus the
injector 35 to its working position (Figure 22 and 23) where it is locked by
the
engagement of the pads 97 with the lock member 73,73. The injector is free to
pivot
in this manner because the lower lock members 72,72, being of circular cross
section,
can rotate in the circular openings on the frame member 95 of the mast.
When in the position of the injector 35 as illustrated on Figure 22 and 23,
the
coiled tubing drilling work in relation to the borehole is commenced and
continued
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until the borehole is completed, or it becomes necessary to return to
operations using
threaded pipe sections. In the case of the latter, the reverse of operations
are carried
out, namely the motors 98 are retracted to allow the injector 35 to tilt to
its unloading
condition so that as the mast is lowered to its loading/unloading inclined
position and
the injector 35 is in a horizontal position upon its support 86. The lock
members 72
and 73 are then hydraulically retracted so that the weight of the injector is
transferred
to its own injector carrier 32 and the mast 33 remains supported on the mast
support
posts 90 of the injector carrier 32. The mast can then be returned to its
vertical
operation position by activation of cylinders 71. The top drive apparatus 70
is then
reactivated into its normal operation.
In the event the operation on the borehole is complete, the mast is raised
again
after the removal of the injector and the top drive apparatus 34 is lowered
into the
lower frame structure 65 prior to the upper frame structure 66 being also
lowered
into its lowered frame structure 65. The coiled tubing is disconnected and
returned to
its reel from the parked injector 35 in the manner described above at which
time the
transport component of the coiled tubing reel can be removed from the site.
The
injector carrier component including the base 85 with the injector 35
supported
thereon is removed from the upper surface 59 of the base 53 of the mast
component
52, and may be separably transported away from the site. The mast 33 can then
be
lowered and the appropriate disconnections made for removing the entire mast
component 52 from the base component 31 before both are separately removed
from
the site.
Various modifications to the disclosed embodiment of the invention will be
obvious to those skilled in the art without departing from the spirit of the
invention as
defined in the appending claims.
