Note: Descriptions are shown in the official language in which they were submitted.
ELEVATED STRUCTURE-MOUNTED LIGHTING SYSTEM
TECHNICAL FIELD
[0001] The present application relates to lighting systems, and more
particularly, to lighting
systems that may be used for a drilling application.
BACKGROUND
[0002] Lighting systems for drilling rigs and their surrounding areas
are critical to ensure
continuous and safe operation of well sites. To ensure even and effective
lighting of the well site,
lighting systems have previously been installed on the uppermost portion of
the drilling rig, also
referred to as the "crown" of the rig. Prior art crown-mounted lighting
systems developed for oil
rigs are limited in several ways. Their designs are complicated and designed
for specific rigs or
rig types. Typically, once they are designed for a particular rig or a
particular type of rig, the
lighting systems designs are limited and are not able to be adapted for other
uses.
[0003] Prior art lighting systems for drilling rigs are fixed,
monolithic structures that are
typically crown or frame systems, with a single size and layout accommodating
one type of light
and rig. Because they are a single structural unit, they are heavy and
typically require cranes along
with multiple workers for installation, removal, and adjustments. A typical
rig lighting frame
system may require between 6 and 12 hours for installation. Further, before a
derrick can be
moved, the lighting systems must be removed¨again with all of the necessary
equipment and
personnel¨and a similar amount of time may be required for uninstallation.
These installation
and uninstallation times extend the time needed between rig deployments. Due
to the high cost of
operating a rig, any such delay is extremely inefficient for the operator of a
wellsite. These factors
also increase the time required to be spent on maintaining these systems,
which also increases
safety risk.
SUMMARY
[0004] An improved elevated structure-mounted lighting system is
disclosed. In addition to
being used on rigs, embodiments of the lighting system may be used with
different applications,
including for drilling, production, refineries, frac sites, construction, and
other industrial
applications that may use tower/mast type equipment. The improved elevated
structure-mounted
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lighting system may accommodate any style or design of crown section of a
drilling rig and may
be mounted on a pole or independent mount system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Embodiments of the present invention are described with reference
to the following
figures. The same numbers are used throughout the figures to reference like
features and
components. Various embodiments may utilize elements and/or components other
than those
illustrated in the drawings, and some elements and/or components may not be
present in various
embodiments. Elements and/or components in the figures are not necessarily
drawn to scale.
[0006] FIG. 1 illustrates a prior art crown-mounted frame-based lighting
system.
[0007] FIG. 2 shows a three-dimensional isometric view of three embodiments
of the
improved elevated structure-mounted lighting system that are depicted relative
to a crown deck.
[0008] FIG. 3 illustrates an elevation view of three embodiments of the
improved elevated
structure-mounted lighting system that are depicted relative to a crown deck.
[0009] FIGS. 4A and 4B are enlarged views of two embodiments of a light
fixture and cap of
a light unit of the improved elevated structure-mounted lighting system.
[00010] FIG. 5 is an enlarged view of an embodiment of a light fixture and a
cap of a light unit
illustrating different positions of the light fixture.
[00011] FIG. 6 is a side view of an embodiment of a light fixture mounting
pole.
[00012] FIG. 7A is a side view of the embodiment of FIG. 6 with a light
fixture that is attached
to rails.
[00013] FIG. 7B is a side view of the embodiment with a single mounting plate.
[00014] FIG. 8 is a perspective view of the embodiment of FIG. 6.
[00015] FIGS. 9A-9F show various configurations of light fixture mounting
embodiments on a
rig.
[00016] FIGS. 10A-10D show various configurations of light fixture mounting
embodiments
on the crown deck of a rig.
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DETAILED DESCRIPTION
[00017]
Fig. 1 illustrates a prior art lighting system 100. The prior art lighting
system is built
from a single frame 120 which includes multiple frame lights 130. The frame
lights 130 are rigidly
fixed onto the frame 120 and cannot be adjusted or repositioned. The frame 120
includes the
electrical connections for the lights. The frame 120 may be installed on the
crown 110, or top, of
a drilling rig such that the ground around the drilling rig is illuminated
when in use.
[00018]
Fig. 2 shows a three-dimensional isometric view and Fig. 3 shows an
elevation view
of three embodiments of the improved elevated structure-mounted lighting
system 200 that are
depicted relative to a crown deck. The embodiments of the lighting system 200
may be mounted
on the crown deck of a drilling rig or on other elements of a frame structure.
The lighting
system 200 is lightweight in design and may be manufactured using any type of
metal, including
aluminum, steel, carbon, hot roll, etc. The frame structure may be hollow to
reduce weight. The
lighting system is also modular, which allows it to be assembled on site
without the use of heavy
equipment, cranes, harnesses, supports, cables, etc. This reduces the risk of
accidents and the time
and costs associated with the same. In an embodiment, a pole-mounted design
may be set up by
two people in under one hour. The system may accommodate a variety of
different light types,
with differing luminosities and power consumption, that may be selected based
on the particular
application. Variations of light types may include combustion-proof and/or LED
lights.
[00019] The lighting system 200 is modular and assembled using multiple
standalone pieces
that may be configured to different structures. Three lighting unit
embodiments from Figs. 2 and 3
are shown in an I-shape 210, T-shape 220, and L-shape 230, but this is not
limiting and other
configurations or modifications may be used, due in part to the modular nature
of the system.
There is no master frame or master support structure, which allows for
configurability and
customization.
[00020] As shown in Fig. 3, the light units 210, 220, and 230 may include a
mounting pole 240,
a bracket for a top rail 242, a bracket for a bottom rail 244, a cap 246, and
a light fixture 248. The
bracket for a top rail 242 and bracket for a bottom rail 244 may be used to
attach the light mounting
pole 240 to rails 205 of a crown deck of a drilling rig using U-shaped bolts
or straps, as shown in
Fig. 2. The straps are wrench-type straps that may be made out of a plastic
composite. In another
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embodiment, the mounting pole 240 may be welded directly to the drilling rig
crown or other
structure.
[00021] In the alternative embodiment shown in Fig. 6, mounting pole 240 may
be attached to
the crown deck or other structure using brackets 300 and 310 that attach to
top rail 242 and bottom
rail 246 respectively. In this particular embodiment, bracket 300 comprises a
top mount plate 320
and a top rail clamp 330, while bracket 310 comprises bottom mount plate 360
and clamp plate
370. One benefit of this alternative embodiment is allowing the use of shorter
mounting poles,
which thereby reduces the overall weight of the system. As shown more clearly
in Fig. 7A, top
mount plate 320 includes a vertical portion 322 that is substantially parallel
to the central axis of
mounting pole 240 and a horizontal portion 324 that is substantially parallel
to the top surface of
top rail 242. Similarly, top rail clamp 330 includes a vertical portion 332
that is substantially
parallel to the central axis of mounting pole 240 and a horizontal portion 334
that is substantially
parallel to the top surface of top rail 242. The horizontal portions of top
mount plate 320 and top
rail clamp 330 are connected together, as for example by one or more bolts, as
shown in Fig. 7.
Alternatively, as shown in Fig. 7A, top mount plate 320 and top rail clamp 330
may be combined
into a single component that hooks over the top of top rail 242.
[00022] Mounting pole 240 is held in place and attached to top rail 242 by the
use of one or
more bolts 340, which are inserted through both top mount plate 320 and top
rail clamp 330. In
the embodiment of Fig. 7A with no separate top rail clamp, bolt(s) 340 are
inserted through both
vertical portions of top mount plate 320.
[00023] Mounting pole 240 may be further held in position using one or more
tube clamps 350,
which are bolted or otherwise connected to top mount plate 320 and/or bottom
mount plate 360.
[00024] Also as shown in Fig. 7A, bottom mount plate 360 includes a vertical
portion 362 that
is substantially parallel to the central axis of mounting pole 240. Optionally
(but not shown),
bottom mount plate 360 may also include a horizontal portion that is
substantially parallel to the
bottom of bottom rail 244. Clamp plate 370 also includes a vertical portion
372 that is substantially
parallel to the central axis of mounting pole 240. Also, optionally (but not
shown), clamp plate
360 may include a horizontal portion that is substantially parallel to the
bottom of bottom rail 244.
Alternatively, as shown in Fig. 7B, bottom mount plate 360 and clamp plate 370
may be combined
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into a single component 336 that hooks over the bottom of bottom rail 242. In
Fig. 7B, bolt 340
may be optional.
[00025] Mounting pole 240 is held in place and attached to bottom rail 244 by
the use of one or
more bolts 380, which are inserted through both bottom mount plate 360 and
clamp plate 370. In
the embodiment of Fig. 7A with no separate clamp plate, bolt(s) 380 are
inserted through both
vertical portions of bottom mount plate 360. Mounting pole 240 may be further
held in position
using tube clamp 350, which is also bolted or otherwise connected to mount
plate 320.
[00026] As shown in Fig. 6, top mount plate 320 and bottom mount plate 360 are
also connected
to each other, using one or more bolts 390 or other fastening devices,
providing further stability
and for this alternative embodiment.
[00027] In addition, top mount plate 320 and bottom mount plate 360 may be
configured with
one or more vertically extending apertures 392 (as shown in FIG. 8), allowing
the two mount plates
to be moved vertically in relation to each other, while still providing the
ability to insert bolt(s) 390
or other fastening devices through both mount plates. The vertically extending
apertures 392 thus
allow this alternative embodiment to be used on crown decks or other
structures with a wide range
of different dimension and configurations.
[00028] The light fixture 248 connects structurally and electrically to the
cap 246, which houses
wiring to accommodate any light fixture 248 that may be attached. The shape or
configuration of
cap 246 is not limited to that reflected in the figures, and other designs may
be used as long as the
cap is capable of being coupled to the light fixture 248. For example, cap 246
may be a metal
bracket onto which the light fixture 248 is attached. Referring to Figs. 4A
and 4B, the light
fixture 248 may be bolted to the cap 246, but is preferably connected to the
cap using a pin-based
engagement. The pins 250 may be removable. Once the light fixture 248 is
engaged with the
cap 246 such that pinholes 252 are aligned, one or more pins 250 may be
inserted to securely
connect the light fixture 248 to the cap 246. Because the pins 250 are
removable, the light
fixture 248 may be disconnected and removed from the cap 246 by removing the
pins 250. The
light fixture 248 and cap 246 are preferably structured so that the light
fixture 248 may be engaged
with the cap 246 to face outward (as shown in Fig. 4A) or to face inward (as
shown in Fig. 5).
This may be accomplished by aligning the pinholes 252 in at least a first
position or in a second
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position. The light fixture 248 may be configured in the outward position for
use and installed in
the inward position for transport.
[00029] Based on the design, more than two positions may be contemplated. For
example, as
shown in Fig. 7A, mounting pole 240 may be configured with a plurality of
pinholes 252. In this
embodiment, where mounting pole 240 is cylindrical, pinholes 252 may be
radially spaced around
the circumference of mounting pole 240. In addition, light fixture 248 may be
connected to
cap 246 by the use of light bracket 400. In this embodiment, as shown in Fig.
7A, light bracket 400
comprises a generally cylindrical portion 402, which extends telescopically
into at least the upper
portion of mounting pole 240. In addition, cylindrical portion 402 is
configured with one or more
pinholes 404 which are configured to be aligned with the one or more pinholes
252 on mounting
pole 240. In this way, pin(s) 250 may be used to maintain light fixture 248 in
a plurality of different
positions simply by removing pin 250 rotating the light bracket 400 until
pinhole 404 aligns with
a different pinhole on mounting pole 240, and reinserting pin 250 in the new
position. While the
cap 246 and light fixture 248 are preferably proximate to the brackets that
couple the light
unit 210, 220, or 230 to the structure, an extension may be used between the
cap 246 and the light
fixture 248 to extend the light fixture 248 away from the structure to which
the light unit 210, 220,
or 230 is mounted.
[00030] Safety cables connected between the light fixture 248 and cap 246 may
be used as a
backup in the event that pins 250 back out or are sheared during an extreme
weather condition.
[00031] Generally, the light units 210, 220, and 230 have a low profile to
minimize the wind
shear forces that may be experienced by the light units at the top of a
structure (such as a rig) to
which they are mounted. In a preferred embodiment, as shown in Figs. 2-8, the
light units
210, 220, and 230 will extend above the crown deck and handrails(s) only as
far as reasonably
necessary for light fixture 248 to be configured such that it is able to
illuminate the ground in the
area surrounding the structure upon which the light unit is mounted.
[00032] As shown in Figs. 2-8, it is also preferable that mounting pole 240 be
formed of a single
unitary piece, rather than multiple separate portions that are joined together
using bolts, screws,
hinges, or other similar connections. Such a design naturally contributes to
the structural stability
of the light unit.
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[00033] With prior art lighting systems, when a square frame is mounted, the
lights are also
fixed and cannot be moved as they are attached to the frame as a single unit.
In contrast, in the
improved elevated structure-mounted lighting system, each light may be mounted
on a standalone
base, and does not have to be attached to a master frame. Referring back to
Figs. 2 and 3, multiple
light units 210, 220, and 230 may be installed on a crown in different
configurations.
[00034] Accordingly, the lights may be individually shifted up, down, left, or
right. Based on
the location of a light unit 210, 220, or 230, if more surface area is
required to be lit on a particular
side, the lights may be configured and directed in that direction, or the
light pole may be adjusted
to achieve optimal surface lighting. Individual LED bulbs may be angled in a
way to produce the
greatest amount of light without dissipation. The lights or LED bulbs may be
used with visors that
are able to direct light in various directions. In an embodiment, efficient
lights allow the lighting
system to be run from 120V or 240V. The lights may come with dimmer, solar,
and/or sensor
options. Using sensors, the lights may be configured to illuminate when a
particular ambient light
threshold is reached, such as at dusk, dawn, or in overcast conditions. The
lights may also utilize
dimmer controllers, such that the lumen output may be adjusted to accommodate
different
conditions or configurations. Using both dimmable lights and sensors, the
lights may be configured
to gradually increase lumen output as ambient light decreases, which would
promote efficient
power consumption. The lights may also be configured for remote operation,
such that the lights
could be turned off or on using a wired or wireless controller from the base
of the rig deck. As
explained in further detail below, the lights may also be powered using a
backup battery, and the
backup battery may be charged using solar power. These factors allow for
lighting to be achieved
more efficiently than prior art lighting systems.
[00035] As one of skill in the art would understand from reading the foregoing
description, it is
not necessary that the light fixtures 248 be attached to the rig or other
structure using mounting
poles that have the particular configuration shown in Figs. 2-8. Consistent
with the modular design
that is central to the present invention, light fixtures may be connected to
the structure using
mounting brackets or other similar means of attachment.
[00036] For example, as shown in the embodiments in Figs. 9A-9F, the light
fixtures 248 may
be installed onto the derrick or mast structure of a rig (Fig. 9E), or they
may be installed on the top
.. (Fig. 9F), side (Figs. 9A-9C), or bottom (Fig. 9D) of the crown deck. As
shown in Fig. 9A, the
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light fixture may be mounted onto a rig using a rig mounting bracket that
directly bolts onto the
side of the crown deck. The light fixture may be mounted onto a light fixture
bracket that
structurally connects to the rig mounting bracket. As shown in Figs. 9B and
9C, the rig mounting
bracket may be mounted to the side of the crown deck using one or more
magnets. Rare earth
magnets, such as neodymium magnets, are able to exert a significant magnetic
pull force over even
relatively small surface areas. For example, two four-inch diameter neodymium
magnets would
be rated for up to 2,600 lbs of pull force.
[00037] As shown in Figs. 10A-10D, various other configurations of rig
mounting brackets may
be used to connect light fixtures 248 to the handrail of the crown deck. Fig.
10A shows a mounting
pole secured to the top of a crown deck of a rig and also secured to two
handrails using U-shaped
bolts. Fig. 10B shows a mounting bracket attached to a single square handrail
using two U-shaped
bolts. Fig. 10C and D show two different examples of a rig mounting bracket
that spans two
handrails and uses multiple U-shaped bolts. The rig mounting brackets may be
secured to the rig
structure using other configurations of bolts, and, as mentioned above, may
also be welded directly
to the rig structure. Rig mounting brackets that span multiple rig structural
elements, such as the
ones shown in Figs. 10B and C that span two handrails, may be able to more
easily support multiple
loads, including multiple light fixtures 248, or a combination of light
fixtures 248 and solar panels.
To accommodate various configurations of rigs and illumination requirements,
the light
fixtures 248 may be mounted to the structure using any combination of the
mounting examples
above.
[00038] Metal safety nets may also be affixed to the crown below the light
units 210, 220,
and 230. In additional to its modular frame design, the lighting system 200
may use consistent nut
and bolt sizes, which allows flexibility and interoperability in its
structural design and assembly.
[00039] The modular nature of the improved elevated structure-mounted lighting
system also
allows for it to be serviced or adjusted while it is erect and installed.
There is a single cable to
connect to a power source from crown to ground. At the lighting junction box,
12 quarter turn
Appletons may be used. Woodhead plugs may also be used on the junction box.
Further, the
improved elevated structure-mounted lighting system does not have to be
removed or taken down
when the derrick or other applications are being transported or moved, which
is allowed because
the cords may be disconnected, rather than removed, during transport. Once
transport is complete,
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the cords may be reconnected. Other features, such as an explosion-proof
control panel on the
ground with power switches may be used. As noted above, due to the high costs
of rig operation,
reducing time for installation and maintenance and improving safety are
significant factors to
reducing operation costs.
[00040] In an embodiment, the light fixtures 248 may be partially or
completely powered by a
solar array. A solar array may include solar panels, a battery unit, a step
converter, and a power
inverter. The solar panels capture solar energy and generate electricity that
can be either used to
power light fixtures 248 (and/or other equipment) or stored in the battery
unit. In a common
configuration, the light fixtures 248 would operate at night and draw
electricity from the battery
unit, using energy collected by the solar panels during the day and stored in
the battery unit. When
ambient light is low, such as during dawn, dusk, or in overcast conditions, or
when additional
illumination is needed, the light fixtures 248 may operate concurrently while
solar energy is being
collected. In instances in which light fixtures 248 require direct current
(DC), a DC-DC step
converter may be used to match the correct voltage input needed by the light
fixtures 248. In
instances in which alternating current (AC) is needed, a power inverter could
be used to convert
DC power, such as the output from the solar panels or the output from the
battery unit, to usable
AC, which may be used by light fixtures 248 or other equipment. Various
combinations of battery
units, step converters, and power inverters may be used to accommodate
different configurations
and requirements of the lighting system 200.
[00041] In an embodiment, the solar panels may be mounted to the handrails of
the crown deck
of a drilling rig. The solar panels may be mounted on their own or share
mounting hardware with
the light units 210. In that sense, one or more solar panels may be mounted to
the mounting
pole 240, to the top rail (242) or bottom rail (244) brackets, or to another
point on mounting
hardware for the light unit. Each solar panel could be mounted in a position
that would optimize
solar collection. In an embodiment, the solar panels mounted such that they
may be moved into
more than one position. One position may preferably serve as an operating
position, while another
position may preferably serve as a travel position. The solar panels may be
configured in the
operating position for use and in the travel position for transport or
storage. In one embodiment,
the solar panels may be separately mounted on other portions of the rig or on
other structures.
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[00042] Many modifications and other implementations beyond those set forth
herein will be
apparent having the benefit of the teachings presented in the foregoing
descriptions and the
associated drawings. Therefore, it is to be understood that the systems and
methods described
herein are not to be limited to the specific implementations disclosed and
that modifications and
other implementations are intended to be included within the scope of the
appended claims.
Although specific terms are employed herein, they are used in a generic and
descriptive sense and
not for purposes of limitation.
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