Note: Descriptions are shown in the official language in which they were submitted.
Mobile Coiled Tubing Unit
INVENTOR(S): Dustin Kos, Marlin Belanger, Preston Kurash
ASSIGNEE: OPTION INDUSTRIES INC.
DOCKET NO.: 68374.7
Cross-Reference to Related Applications
[0001] This application claims the priority benefit of U.S. Provisional Patent
Applications
61/657,548 filed June 8, 2012 and 61/701,448 filed September 14, 2012.
Field of the Invention
[0002] The present invention is directed to the field of oil and gas drilling
and well servicing
operations, and in particular to mobile coiled tubing rigs used in oil and gas
drilling and well
servicing operations.
Background
[0003] Coiled tubing is a continuous string of steel tubing that is rolled
onto a spool, and is
used for a wide range of oil field services, including but not limited to
drilling, logging,
cleanouts, fracturing, cementing, underreaming, fishing, completion and
production.
[0004] To facilitate coil tubing operations, mobile coiled tubing units, or
rigs as they are also
known, have been developed that can be easily transported to and from the
relevant well site.
The rigs comprise certain conventional elements, namely: a wheeled platform or
frame
.. forming the base of the rig, a reel to store and dispense the coil tubing
string as needed, an
injector head that is used to insert and retract the coiled tubing string from
the well bore, some
form of mast or hoist to elevate the injector above the well head, a control
center for the
operator, a power source for system power. In many instances, to facilitate
ease of transport,
the unit comprises a tandem/tri-drive truck and dedicated coil rig chassis
such as a flat bed
trailer.
Date Recue/Date Received 2020-09-08
CA 02818286 2013-06-10
[0005] Existing mobile coiled tubing rigs having certain limitations. The
various elements
comprising the unit, in particular the spool of coiled tubing, are extremely
heavy and if they
not balanced correctly with respect to each other then the stability of the
mobile platform
during transport can be greatly impaired. Such instability can compromise the
safe handling
of the rig, especially during highway driving conditions. Further, on existing
mobile coiled
tubing rigs the various elements are in fixed positions dictated by the need
to have certain
required spacing between the coil and the injector during the performance of
the down hole
work. This fixed positioning of the various elements greatly impairs the
mobility of the rig
because the weight distribution in uneven and suboptimal to balanced transport
and often
results in certain axle grouping arising that is over the allowed weight.
[0006] Rough and uneven terrain also poses a challenge to existing mobile
units. In
particular, the limited clearance between the ground and the bottom of the
coiled tubing spool
often restricts the ability of the mobile unit to traverse uneven ground. This
can be
problematic given the remote nature of a great many well sites.
[0007] Another limitation of existing mobile units is the limit placed on mast
size. The
physical size of the mobile platform that the elements are mounted on are
strictly regulated by
transportation laws, and this coupled with the need to promote stability in
accordance with all
applicable transportation regulations, dictates the maximum mast length that
can be used.
This frequently results in the use of a mast length that is shorter than the
optimal length for
coiled tubing operations.
[0008] A further limitation of existing mobile coiled tubing units is the
difficulty in aligning
the injector and lubricators with the well head. Limited movement of the mast
results in the
need to repeatedly move the entire apparatus using the tractor until alignment
is achieved.
Movement of the entire apparatus with a tractor is time consuming and
difficult. As a result,
coiled tubing operations are frequently conducted without optimal alignment
which poses
obvious safety risks. Existing mobile units also have limited capacity to
readily maintain the
alignment of the injector with the well head following the addition and
removal of lubricators
which alters the relative height and alignment of the injector to the well
head.
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[0009] A further limitation faced by operators of existing mobile coiled
tubing units arises by
virtue of transportation and hauling regulations and rules that differ across
various
jurisdictions. In particular, each jurisdiction has particular weight and
balance guidelines for
trailers and as such, while a mobile unit may comply in one province, state or
territory, it may
not comply in another. This is problematic during long haul tranSportations,
or if the well site
straddles the boundary between two jurisdictions. Currently, with certain
prior art mobile
coiled tubing rigs, the reel has to actually be removed and transported
separately because of
non-conformity with the relevant transportation rules and regulations,
[0010] What is needed is a mobile coiled tubing rig that mitigates at least
some of the
limitations of the prior art.
Summary of the Invention
[0011] In one aspect, the invention may comprise a mobile coiled tubing rig
comprising:
(a) an elongate frame having a longitudinal axis, the frame being orientated
in substantially
horizontal plane;
(b) a coiled tubing reel rotatably mounted on the frame, the reel being
movable longitudinally
along the frame, and vertically in relation to the frame;
(c) a mast assembly comprising a mast pivotally mounted to the frame, the mast
being
moveable between a first closed position whereby the mast is in a
substantially horizontal
orientation and a second open position whereby the mast is in a substantially
vertical
orientation; and
(d) an injector mounted on the mast, the injector being selectively movable
along the length of
the mast.
In one embodiment, the mast assembly may comprise a mast base which is
moveable
longitudinally along the frame. The mast assembly may also comprise a mast
sleeve within
which the mast may telescopically extend or retract. The rig may further
comprising a
plurality of retractable support jack assembly, each support jack assembly
comprising a
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support jack and a telescoping horizontal cylinders affixed to the frame, the
support jack
assemblies being moveable between a horizontal storage position and a deployed
position
wherein the support jacks engage the ground beneath the frame, and wherein the
telescoping
horizontal cylinders may be used to actuate lateral movement of the frame
relative the support
jacks when in the deployed position.
[0012] In one embodiment, the reel assembly may comprise a vertical lift
mechanism
comprising a horizontal pivot and a hydraulic cylinder to pivotably lift or
lower the reel
assembly. The reel assembly may be mounted to a slide track on the frame, and
is pushed or
pulled along the slide track by a hydraulic cylinder. The reel assembly may
comprises a reel
drive comprising a rack and pinion drive driven by a closed-loop hydraulic
motor.
[0013] In one embodiment, the mast assembly may comprise a pair of mast
sleeves and a pair
of parallel masts, interconnected by at least one cross member, wherein one
end of the at least
one cross member is pivotably attached to one mast and the other end is
removably latched to
the other mast.
[0014] In another aspect, the invention may comprise a mobile coiled tubing
rig comprising:
(a) an elongate frame having a longitudinal axis, the frame being orientated
in a substantially
horizontal plane;
(b) a coiled tubing reel assembly mounted on the frame;
(c) a mast assembly comprising a mast pivotally mounted to the frame, the mast
being
moveable between a first closed position whereby the mast is in a
substantially horizontal
orientation and a second open position whereby the mast is in a substantially
vertical
orientation, wherein the mast assembly comprises a mast base which is moveable
longitudinally along the frame; and
(d) an injector mounted on the mast, the injector being selectively movable
along the length of
the mast.
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In one embodiment, the mast assembly may comprise a mast sleeve within which
the mast
may telescopically extend or retract. The reel assembly may be movable
longitudinally along
the frame, and vertically in relation to the frame.
Brief Description of the Drawings
[0015] In the drawings, like elements are assigned like reference numerals.
The drawings are
not necessarily to scale, with the emphasis instead placed upon the principles
of the present
invention. Additionally, each of the embodiments depicted are but one of a
number of
possible arrangements utilizing the fundamental concepts of the present
invention. The
drawings are briefly described as follows:
[0016] Figure 1 is a side view of one embodiment of the apparatus of the
present invention
coupled to a tractor, booster and jeep.
[0017] Figure 2 is a side view of one embodiment of the apparatus of the
present invention
coupled to a tractor, booster and jeep, and having a control cabin.
[0018] Figure 3 is a side view of one embodiment of the apparatus of the
present invention
with the mast disassembled and removed.
[0019] Figure 4 is a top view of one embodiment of the apparatus of the
present invention
coupled to a tractor.
[0020] Figure 5 is a view of one embodiment of the apparatus of the present
invention with
the mast not raised. Figure 5A is a detail view on one portion of Figure 5.
[0021] Figure 6 is a side view of one embodiment of the apparatus of the
present invention
with the mast raised.
[0022] Figure 7 is a perspective view of one embodiment of the apparatus of
the present
invention with the mast raised.
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[0023] Figure 8 is another perspective view of one embodiment of the apparatus
of the present
invention with the mast raised.
[0024] Figure 9 is an elevated side view of one embodiment of the apparatus of
the present
invention with a control cabin and without a mast,
[0025] Figure 10 is a view of a reel assembly of one embodiment of the
apparatus of the
present invention. Figure 10A shows a view of the reel assembly and showing
the reel axle.
Figure 10B shows the reel assembly apart from the rig. Figure 10C shows the
reel axle clamp.
Figure 10D shows the end of the reel axle.
[0026] Figure 11 is a view of the reel drive system of one embodiment of the
apparatus of the
present invention.
[0027] Figure 12 is a partial side view of one embodiment of the apparatus of
the present
invention with the mast raised and the sliding base in the rear most position,
[0028] Figure 13 is a partial side view of one embodiment of the apparatus of
the present
invention with the mast raised and the sliding base in the forward most
position.
[0029] Figure 14 is a partial elevated rear view of one embodiment of the
apparatus of the
present invention with the mast raised.
[0030] Figure 15 is an elevated side view of one embodiment of the apparatus
of the present
invention with the mast raised.
[0031] Figure 16 is an elevated front view of one embodiment of the apparatus
of the present
invention with the mast raised. Figure 16A is a detailed view of a portion of
Figure 16
showing a partial view of the cradle and mast members of one embodiment of the
apparatus of
the present invention.
[0032] Figure 17 is a view of the level wind apparatus of one embodiment of
the apparatus of
the present invention. Figures 17A is a view of the encoder of the level wind
assembly of one
embodiment of the apparatus of the present invention. Figure 17B is a view of
the level wind
screw and worm gear drive box of the level wind assembly of one embodiment of
the
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apparatus of the present invention. Figure 17C is a view of the tubing guide
of the level wind
assembly of one embodiment of the apparatus of the present invention.
[0033] Figure 18 is a diagrammatic depiction of a reel and level wind assembly
of one
embodiment of the apparatus of the present invention.
= Detailed Description of Embodiments
[0034] The invention relates to a mobile coiled tubing unit. When describing
the present
invention, all terms not defined herein have their common art-recognized
meanings. To the
extent that the following description is of a specific embodiment or a
particular use of the
invention, it is intended to be illustrative only, and not limiting of the
claimed invention. The
following description is intended to cover all combinations of features,
alternatives,
modifications and equivalents that are included in the spirit and scope of the
invention, as
defined in the appended claims.
[0035] In this description the terms "coiled tubing", "coiled tubing string"
shall be used
interchangeably but in each instance shall mean the continuous steel tube pipe
used in oil and
gas drilling, production and maintenance operations.
[0036] The present invention is directed to a mobile coiled tubing unit, or
rig as it is also
known, having a moveable coiled tubing reel or a moveable mast, or both a
moveable reel and
mast. In one embodiment, the unit is configured for transport using a moveable
coiled tubing
reel and a moveable mast that is retractable into a mast sleeve to achieve
dimensional
requirements for transport. The apparatus itself can be moved laterally using
retractable jacks
and hydraulic cylinders for well alignment and moving from one well to the
next. In one
embodiment, the mast base moves forward and back to achieve well head
alignment and
injector alignment in various positions without need of repositioning or
altering rig heights.
The reel can also be raised to increase clearance to facilitate transportation
over rough or
uneven terrain, thereby allowing the rig to accommodate a larger reel.
[0037] Figure 1 depicts one embodiment of a rig (50) configured as a wheeled
trailer coupled
to a tractor (52). The rig comprises a substantially rectangular horizontal
frame (12) having a
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longitudinal axis. The various mechanical elements of the rig (50) are mounted
on or to the
frame (12). The rectangular frame (12) has a front end (11) that is closest to
the tractor during
transportation and a rear end (13) that is furthest from the tractor (52)
during transportation,
and two longer sides connecting the two ends (11, 13). Although the
embodiments described
herein depict the rig (50) as a wheeled trailer, it can be understood that
other suitable
transportation means may be employed. For example, the apparatus could be skid
mounted,
or track systems could be used instead of wheels.
[0038] The frame (12) comprises cross members (17) spanning the trailer in an
orientation
that is perpendicular to the longitudinal axis. In one embodiment, the frame
members are
reinforced or have greater structural strength in the vicinity of the reel.
[0039] The frame (12) has a plurality of ground-engaging wheels (14) proximate
to its rear
end (13) and a hitch (18) proximate to its front end (11). In one embodiment,
the hitch (18)
consists of a king pin that mates with fifth wheel mounted on the tractor
(50). The hitch (18)
and wheels (14) allow the apparatus (50) to be towed by a tractor (52) in a
conventional
manner. In one embodiment, a booster component attached to the back of the
frame and/or a
jeep disposed between the truck and the frame may be used to increase the
capacity of the
combined truck and trailer by distributing weight to the extra wheels. They
can be used
separately or together as needed in order to help the unit conform to highway
weight
regulations. During operation, the rig (50) may be decoupled from the tractor
(52) and
stabilized in a horizontal orientation using retractable hydraulic rig jacks
(9) located proximate
to each corner of the rectangular frame (12). Additional jack stands (9A) may
be provided for
use when the rig is not in use and not coupled to a tractor or jeep.
[0040] In one embodiment, a control cabin (16) is mounted on the frame in
position
proximate to the front end (11). The control cabin (16) contains all of the
controls and
instrumentation necessary to operate the apparatus (50). The control cabin may
be provided
on a separate trailer unit, or the unit may be remotely controlled.
[0041] A coiled tubing reel (46) is mounted on an axle (48) extending the
width of the frame
(12) and attached at each end to a reel drive frame assembly (66) mounted on
the long sides of
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the frame (12). In one embodiment, the reel is approximately longitudinally
centred on the
frame. In the embodiment shown in the Figures, the reel axle is driven by
hydraulic motors
(70) through a pinion gear box (64) and a drive adapter plate (68), all of
which is mounted on
the reel drive frame assembly (66). The drive adapter plate has a keyed
opening which mates
with an axle adapter plate (69) fixed to the end of the axle (48). This
configuration permits
the reel axle (48) to slide into the drive adapter plates (68) during
assembly. The adapter
plates are fixed together with a drive clamp (67) which encircles the adapter
plates (68, 69).
The drive clamp may comprise of two semi-circular portions which are hinged
together at one
end, and which bolt together at the other.
100421 In one embodiment, a closed-loop hydraulic motor (70) is used to
control the torque
being placed on the reel drive system, and tension of tubing between the reel
and injector.
100431 In one embodiment of the present invention, the reel assembly comprises
a level wind
assembly (71). The level wind assembly (71) positions the tubing (not shown)
as it is being
wound onto the reel (46). The level wind assembly (71) is comprised of a
tubing guide (75), a
level wind screw (72), and a hydraulic worm drive gear box (74), a controller
and an encoder
(73). The lateral position of the tubing guide (75) is controlled by the
controller which
determines the rotation of the level wind screw (72). In one embodiment, the
level wind screw
is driven through an enclosed hydraulic drive gear box (74), although other
drive mechanisms
such as a conventional chain and sprocket drive system may also be suitable.
The worm drive
gear box system reduces moving parts subject to wear and improves control of
the tubing
position on the reel. Tubing size adjustments can be made remotely with the
controller so no
mechanical changes need to be made. An encoder (73) accurately determines the
lateral
position of the tubing guide and the information is sent to the controller
that controls the
hydraulic worm drive (74).
[00441 The reel drive frame assembly (66) and the axle (48) and the reel (46)
mounted
thereon, are movable backwards and forwards along slide tracks (23) mounted on
the frame
(12). Accordingly, the reel (46) may be moved to a position more proximate to
the front end
(11), or more proximate to the rear end (13) as desired by the operator, or
for transport
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purposes. The longitudinal actuation of the reel assembly (66) may
accomplished with a pair
of hydraulic cylinders (22).
[0045] The reel may also be raised vertically by pivoting the reel drive frame
assembly (66)
upwards about a pivoted connection (27) between the reel drive frame assembly
(66) and the
slide track (23), as shown in Figure 7. As such, the reel (46) may be elevated
relative to the
frame, which may create greater clearance between the ground and the lowest
point of the reel
(46). The pivoting actuation of the reel assembly (66) may be accomplished
using more
hydraulic cylinders (26), as may be seen in Figure 10.
[0046] The ability to move the reel (46) both longitudinally and vertically
may provide several
advantages. First, the reel (46) can be raised to increase clearance thereby
facilitating
transportation of the rig (50) over rough or uneven terrain. Second, the reel
(46) when loaded
with coiled tubing is extremely heavy, and the longitudinal and vertical
movement of the reel
(46) can be used to balance the load so that the apparatus (50) is more stable
during
transportation. For example, the reel (46) may be moved towards the second end
(13) during
transport and towards the first end (11) during operation. Furthermore,
different jurisdictions
have differing weight balance guidelines, rules and regulations for mobile
coiled tubing rigs,
and thus the ability to move the reel (46) may allow conformity with the rules
of the relevant
jurisdiction.
[0047] Mounted at the rear end (13) of the frame (12) is a mast assembly
comprising a mast
base (1). A mast sleeve (7) is pivotally mounted on the mast base (1). A mast
(4) is slidably
mounted within the mast sleeve (7) and has an upper end (38) and a lower end
(40). A
hydraulic cylinder (6) is used to extend or retract the mast (4) within the
sleeve (7). In one
embodiment, the sleeve is open at the bottom end, so that the bottom of the
mast may protrude
when in a lowered position. In one embodiment, the mast (4) may comprises two
parallel
masts each having its own mast base (1) and sleeve (7), interconnected by
cross members (34)
and a base cross member (1A). In one embodiment, one or more of the cross
members (34)
may be removably latched at one end and may be pivoted out of the way using a
cylinder (35)
to allow the cradle (60) to pass, as shown in Figures 13 and 14.
CA 02818286 2013-06-10
[0048] A pair of hydraulic cylinders (44) actuate the mast sleeve and mast
between a transport
position where the mast is substantially horizontal as shown in Figure 1, and
an operable
position where the mast sleeve (7) and mast (4) are substantially upright as
shown in Figure 6.
An elevated support structure (42) located proximate to the front end (11) of
the frame
supports the mast (4) when in its closed transport position.
[0049] A cradle (60) supports the injector (5) and goose neck (20) and is
slidably moveable
along the length of the mast (4). During transportation, the cradle (60),
injector (5) and goose
neck (20) are lowered to the lower end (40) of the mast (4). In one
embodiment, the goose
neck (20) is comprised of hinged parts to allow it to be transported in a
folded configuration.
To facilitate coiled tubing operations, when the mast is raised, in one
embodiment, the cradle
(60) is raised up the mast (4) by hydraulic motors driving pinion gears that
engage a gear rack
on each side of the mast (not shown). When the mast is raised to an operating
position, and
the cradle (60) is raised towards the upper end (38) of the mast (4),
lubricators (28) and a blow
out preventer (32) may be suspended beneath the injector (5) and are connected
to the well
head (30) in conventional manner.
[0050] The mast base (1), and correspondingly the mast sleeve (7) and the mast
itself (4), are
movable along the longitudinal axis (A) of the apparatus (50) by means of a
sliding track (3)
and a pair of hydraulic cylinders (2). In one embodiment, the mast base (1)
can be extended
such that it overhangs the rear end (13) of the frame (12) as shown in Figure
12 or can be
moved to a position more proximate to the front end (11) as shown in Figure
13. The ability
to selectively move the mast (4) longitudinally facilitates balancing of the
apparatus (50) for
transportation in the same manner as described above for the reel (46) but
also facilitates
movement of the mast to align the injector (34) and lubricators (28) with the
well head (30)
without having to move the entire apparatus (50) and without having to use the
tractor (52) to
move the apparatus (50).
[0051] In one embodiment, retractable hydraulic rig jack assemblies comprising
rig jacks (9)
are located at each corner of the rectangular frame (12), and each rig jack
(9) is hingedly
connected to a telescoping cylinder (10) that moves horizontally in and out of
the frame (12),
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When the apparatus is in a desired position, the telescoping cylinders (10)
extend the jacks
outwards. The jacks (9) are then deployed downwards to support the weight of
the apparatus.
As a result, the telescoping nature of the telescoping cylinders (10) allows
lateral movement of
the entire apparatus (50) when the weight of the apparatus (50) is supported
by the jacks (9).
The operator can utilize this lateral movement to align the injector (5) and
lubricators (28)
with the well head (30). During transportation, the retractable jacks (9) fold
up and insert into
the telescoping cylinders (10) and the telescoping cylinders (10) retract into
the frame (12).
[0052] Accordingly, it can be understood that after the apparatus (50) has
been positioned
proximate to the well head (30) using the tractor, the cylinders (10) and
jacks (9) are deployed
to stabilize the apparatus (50) and the tractor (52) is decoupled. The reel
(46) is moved into its
operational position using the associated cylinders (22) and the mast is
raised into its
substantially vertical operational position using associated cylinders (44).
The operator is then
able to utilize the longitudinal movement of the mast (4) on the sliding
tracks (3), and the
lateral movement of the apparatus (50) using the cylinders (10) and jacks (9),
the height of the
mast (4) using the cylinders (6) to raise and lowers the mast within the
sleeve (7), and the
ability to raise and lower the injector (5) up and down the mast (4) in the
cradle (60) to
precisely align the injector (5) and the lubricators (28) with the well head
(30). As lubricators
(28) are added or removed depending on the nature of the coiled tubing
operation, the operator
may utilize the same movement capabilities to facilitate alignment of the
injector (5) with the
well head (30). The ability to alter the relative position of the various
components of the
apparatus, and the ability to move the apparatus (50) laterally, greatly
reduces the time and
effort required to achieve alignment in comparison to existing rigs,
[0053] During transportation, the mast (4) is fully retracted into the sleeve
(7) thereby
ensuring that the upper end (38) of the mast (4) does not protrude beyond the
tractor (52).
During operation, the mast (4) can be extended from the sleeve (7) to give the
mast (4)
additional height. Also, the operator can also retract or extend the mast (4)
incrementally to
assist with alignment of the injector (5) with the well head (30) and allows
the operator to run
the injector (5) in a relatively tall or short configuration.
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[0054] In one embodiment, for smaller units the mast (4) may be transported
separately and
assembled and installed on the rig at site. As such, the rig would transport
the reel and the
injector between sites, as shown in Figure 9.
[0055] In another embodiment of the present invention, the control cabin may
be a remote
location on a separate trailer unit, In a further embodiment, the separate
trailer unit may also
comprise of any or all of a hydraulic accumulator for the blow out preventers,
a HPU
(Hydraulic Power Unit), a control cabin, a fuel tank, a generator and a tool
room and a tool
room,
[0056] Further, in the embodiments described above, hydraulic cylinders are
utilized to move
various components of the rig such as the reel (46), the mast base (1), mast
(4), telescoping
cylinders (10) and support jacks (9). One skilled in the art will understand
that there may be
other suitable mechanical means to achieve such movement such as rack and
pinion drives
with electric or hydraulic motors, or chain drives or cable drives, without
deviating from the
scope and spirit of the present invention.
[0057] As will be apparent to those skilled in the art, various modifications,
adaptations and
variations of the foregoing specific disclosure can be made without departing
from the scope
of the invention claimed herein.
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