[0001] The present invention relates to a modular drilling rig system, a method for bringing
a modular transfigurable drilling rig system into an operational mode, and a method
for bringing a modular transfigurable drilling rig system from a field transport mode
into an operational mode.
[0002] Modular drilling rigs have been used in the oil and gas industry, both in offshore
drilling industry and on land for a considerable time. An early example of such a
modular drilling rig is described in
US 3,228,151. In this document a drilling apparatus is disclosed comprising a base substructure
having a base, an elevatable drilling floor and means between them for raising the
floor, preferable hingable legs. A mast is provided, having rear legs extending upward
from the substructure and front legs extending downward in front of the substructure,
pivotal means supporting the front legs. The mast is swingable on said pivotal means.
[0003] Improvements to modular drilling rigs have been described by the same applicant in
WO2013133699,
WO2013133698,
WO2014178712. It is an aim of the invention to provide a more efficient modular drilling rig system.
[0004] From
US2004/0211598 a method and apparatus for transporting and assembling a drilling rig is disclosed.
The lower section is transported via a trailer to the drill site with a top drive
already installed within the lower section. At the drill site, the trailer is brought
into alignment with a bottom section.
[0005] From
US2012/167485 a high-capacity drilling rig system is known comprising a transport trailer having
a first support member and a drive member which align the lower mast portion with
inclined rig floor ramps and translate the lower mast legs up the ramps and into alignment
for connection.
[0006] A first aspect of the invention relates to a modular transfigurable drilling rig
system composed of multiple components, which system is transfigurable between a transport
mode in which the components of the system are transportable by vehicles and an operational
mode in which the components are assembled to a drilling rig which is adapted to perform
drilling and/or wellbore related activities, e.g. drill into a well centre in the
ground, the drilling rig system comprising:
- a base structure adapted to be positioned in the operational mode on the ground;
- a drilling rig mast having a top end and a foot end, composed of multiple transportable
mast sections, said mast sections at least including a lower mast section comprising
the foot end of the mast, the lower section being connectable to the base structure,
and a top mast section comprising the top end of the mast, and preferably one or more
intermediate mast sections,
wherein preferably mast sections have a U-shaped horizontal cross section with a left-hand
mast wall, a rear mast wall, and a right-hand mast wall, and with an open front,
wherein preferably mast sections are provided with one or more vertical rails adapted
to guide a top drive unit,
which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position, e.g. vertically above a well center;
- a top drive unit adapted to be positioned in the drilling rig mast so as to perform
drilling activities and advantageously be guided by said one or more vertical rails
allowing for vertical motion of the top drive unit relative to the mast.
[0007] The top drive unit is an expensive and complex piece of machinery that requires careful
handling. Also the actual top drive unit suitable for a particular drilling activity
may vary from one suitable for another drilling activity.
[0008] It is therefore desirable to provide a modular transfigurable drilling rig system
that allows for easy and careful handling and/or exchange of the top drive unit.
[0009] The invention proposes a transfigurable drilling rig system wherein the drilling
rig system further comprises a temporary removable vehicle transportable top drive
unit installation device that comprises a frame that is adapted to receive the top
drive unit so as to transport the installation device with the top drive unit therein
by a vehicle,
wherein the frame of the installation device is positionable in line with an end of
a mast section of the mast in said substantially horizontal mast assembly position,
e.g. of an intermediate mast section of the mast prior to assembly of the top mast
section, wherein, for example, the frame is provided with one or more alignment and/or
connection members, e.g. hooks, to align and/or connect the frame with the respective
mast section, so as to be able to transfer the top drive unit from the frame of vehicle
transportable top drive unit installation device (130) into the drilling rig mast
in the substantially horizontal mast assembly position thereof, prior to removal of
the vehicle transportable top drive unit installation device. Hereafter, the drilling
rig mast with the top drive is allowed to move towards its vertical operational position.
[0010] In embodiments, the temporary removable installation device comprises a top drive
unit translation assembly with a translation drive to transfer, e.g. slide, the top
drive unit from the frame of the installation device into the drilling rig mast in
the substantially horizontal mast assembly position thereof. Alternatively, a separate
translation drive is provided.
[0011] Advantageously, the translation drive comprises a winch and a winch driven cable
connectable to the top drive unit and adapted to transfer, e.g. slide, the top drive
unit into the mast in its substantially horizontal assembly position. Alternative
drive include a cylinder, chain drive etc. etc.
[0012] In embodiments, the frame comprises one or more rails that are aligned with said
one or more rails of the mast when the frame of the installation device is positioned
in line with an end of a mast section of the mast in said substantially horizontal
mast assembly position, and wherein the top drive unit comprises one or more rail
followers that are engaged with the one or more rails of the frame prior to said transfer
into the mast and then are engaged with said one or more rails of the mast upon transfer
into the mast. This ensures a proper alignment and safe transfer of the delicate equipment.
[0013] In embodiments, the mast is adapted to be - in its substantially horizontal assembly
position - with its open front facing down, e.g. said open front at a height of less
than 1 metre above the ground.
[0014] In embodiments, the mast sections comprise left-hand and right-hand vertical front
posts and rear corner posts, with each front post being connected by bracings to a
respective rear corner post to form the respective side wall of the mast and said
rear corner posts being connected to each other by bracings to form the respective
rear wall of the mast, and wherein, preferably, a vertical rails is fixed to each
of the front posts and the top drive unit is guided along said vertical rails. Such
a construction is extremely solid and safe.
[0015] In embodiments, the top mast section comprises a crown block assembly with cable
sheaves mounted to the top mast section and a travelling block assembly with cable
sheaves, wherein, preferably, one or more cables are pre-reeved over said crown block
and travelling block assembly. Such pre-reeving increases the on-site efficiency.
[0016] In embodiments, the drilling rig system further comprises at least one drive assembly
to move the drilling rig mast with the top drive between the substantially horizontal
mast assembly position and the vertical operational position. Alternatively, a separate
drive is provided to erect the drilling rig mast.
[0017] In embodiments, an intermediate mast section of the mast comprises a drag chain with
one or more electrical and/or hydraulic lines connectable to the top drive unit.
[0018] The invention also provides a method for bringing the modular transfigurable drilling
rig system into operational mode comprising:
- placing the base structure on the ground,
- positioning the lower mast section in a generally horizontal position thereof such
that the foot end of the lower mast section is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- positioning one or more further drilling rig mast sections in substantially horizontal
position thereof in line with the lower mast section and interconnecting said mast
sections;
wherein the method further comprises:
- positioning the vehicle transportable top drive unit installation device in line with
the end of a mast section of the mast in said substantially horizontal mast assembly
position, e.g. of an intermediate mast section of the mast prior to assembly of the
top mast section,
- transferring, e.g. sliding, the top drive unit from the frame of the installation
device into the drilling rig mast in the substantially horizontal mast assembly position
thereof;
- removing the frame of the temporary removable vehicle transportable top drive unit
installation device, prior to moving the drilling rig mast with the top drive unit
towards its vertical operational position.
[0019] In embodiments, the installation device comprises a top drive unit translation assembly
with a translation drive to transfer, e.g. slide, the top drive unit from the frame
of the installation device into the drilling rig mast in the substantially horizontal
mast assembly position thereof. In such embodiments, a possible method of the invention
further comprises the step of operating the translation drive of the top drive unit
translation assembly to transfer, e.g. slide, the top drive unit from the frame of
the installation device into the drilling rig mast in the substantially horizontal
mast assembly position thereof.
[0020] In embodiments, the translation drive comprises a winch and a winch driven cable
connectable to the top drive unit. In a possible method of the invention the winch
is operated to transfer, e.g. slide, the top drive unit into the mast in its substantially
horizontal assembly position.
[0021] In embodiments, the frame comprises one or more rails that are aligned with said
one or more rails of the mast when the frame of the installation device is positioned
in line with an end of a mast section of the mast in said substantially horizontal
mast assembly position, and wherein the top drive unit comprises one or more rail
followers that are engaged with the one or more rails of the frame prior to said transfer
into the mast and then are engaged with said one or more rails of the mast upon transfer
into the mast.
[0022] In embodiments, the mast is assembled - in its substantially horizontal assembly
position - with its open front facing down, e.g. said open front at a height of less
than 1 metre above the ground.
[0023] In embodiments, the top drive unit installation device is offloaded from a road vehicle
and positioned in line with and connected to the respective mast section, and wherein
the top drive unit is subsequently transferred into the mast.
[0024] In embodiments, the temporary removable vehicle transportable top drive unit installation
device is positioned in line with the end of an intermediate mast section of the mast
in said substantially horizontal mast assembly position, and wherein the top drive
unit is then transferred into said intermediate mast section, and wherein the frame
of the installation device is then removed, and wherein subsequently the top mast
section is positioned in line with the already assembled part of the mast and connected
thereto.
[0025] In embodiments, the top mast section comprises a crown block assembly with cable
sheaves mounted to the top mast section and a travelling block assembly with cable
sheaves, wherein, preferably, one or more cables are pre-reeved over said crown block
and travelling block assembly. Advantageously, the method comprises the step of connecting
the travelling block assembly to the top drive unit that has been transferred into
an adjoining intermediate mast section, e.g. wherein the travelling block assembly
comprises a hook that is engageable with the top drive unit.
[0026] It will be appreciated that the first aspect of the invention can be readily combined
with one or more of the other aspects of the disclosure as described herein and/or
with one or more optional and/or preferred features as described herein primarily
with reference to said one or more other aspects of the disclosure.
[0027] According to a second aspect of the invention this is achieved in that the modular
transfigurable drilling rig system composed of multiple components, which system is
transfigurable between a field transport mode in which components of the system are
transportable on the field by vehicles between multiple well centers, and an operational
mode in which the components are assembled into a drilling rig which is adapted to
drill into a well centre in the ground of the field, the system comprising:
- a drilling rig mast having a top end and a foot end, which is movable between a substantially
horizontal mast assembly position and an operational position substantially vertically
above the well centre, the drilling rig mast including:
∘ a lower section, comprising the foot end of the mast, the lower section being connectable
to a base structure, and
∘ a top section, comprising the top end of the mast and a top drive,
- at least one drive assembly to move the drilling rig mast with the top drive between
the substantially horizontal mast assembly position and the vertical operational position,
- a base structure adapted to be positioned in the operational mode in a H-shape on
the surface adjacent a well centre to support the drilling rig mast thereon, which
base structure is adapted to be transported by a vehicle, the H-shaped base structure
comprising an assembly of interconnected parts, including:
∘ a first set of support beams adapted to be positioned on the surface with the well
center there between, the first set of beams extending in a first direction, which
support beams are adapted to accommodate transport wheels, at least in the field transport
mode; and
∘ a second set of support beams adapted to be placed on the surface and extending
in a second direction opposite to the first direction,
- transport wheels, adapted to be accommodated by the first set of support beams,
- a transport connection assembly which is adapted to in the field transport mode be
provided between the vehicle and the second set of support beams in order to transport
the base structure as a whole.
[0028] The provision of transport wheels and a transport connection assembly facilitates
within field movements of the modular transfigurable drilling rig system. Within field
moves are e.g. advantageous when the system is applied for fracking.
[0029] For example with fracking, on a field, also known as well pad or pad, multiple wells,
for example ten wells or more, are drilled relative close to each other. The invention
facilitates transport of the transfigurable drilling rig system on the field, for
example from one well center to another well center, with the transfigurable drilling
rig system in its field transport mode.
It is noted that transport of drilling rig systems between fields, or well pads, often
requires transport over public roads, which brings with it stringent dimensional constraints
regarding the configuration of the drilling rig. Typically, a modular drilling rig
is configured such that it can be transfigured into a transport mode, which transport
mode enables on field transport and also allows for transport between fields or pads.
The on field transport mode according to the invention provides a third configuration,
which allows for transportation of the drill rig between wells but does not require
full disassembly into the transport mode, it therefore reduces down time in case of
on field transport between well centres compared to on field transport between well
centres using the transport mode.
[0030] In embodiments, the H-shaped base structure is obtained by a cross part which is
an integral part of one or both of the first set of support beams, and/ or one or
both of the second set of support beams. For example, the cross part is formed as
an integral part of a support beam, such that the support beam is "L-shaped" when
seen from above. Together with the other support beams, the base structure is formed
in a H-shape. It is also conceivable that two support beams comprise a protruding
part extending perpendicular to the first or second direction, such that the cross
part is formed by both protruding parts.
[0031] In particular embodiments, the transportable base structure further comprises a cross
beam adapted to be positioned on the ground near the well centre, to which at least
one of the first and/or second set of support beams is connected in the operational
mode.
[0032] In embodiments, the cross beam being of a foldable design, allowing the cross beam
to be folded out in the operational mode and folded in in the field transport mode
such that the mutual distance between the support beams is reduced. Hence, the 'legs'
of the H-shaped base structure are movable towards each other to decrease the width
of the 'H'. This is advantageous if the H-shaped base structure is too wide to be
transported as a whole.
[0033] In embodiments, the lower section of the drilling rig mast further comprises drilling
drawworks. Alternatively, the drawworks are positioned on the surface adjacent the
drilling rig mast, and are separately transported. As the drilling drawworks is a
voluminous and heavy-weight component, it is common to transport the drilling drawworks
seperately from the lower section.
[0034] In embodiments, the lower section of the drilling rig mast further comprises a pedestal,
adapted to support the drilling rig mast above the well centre in the operational
mode. Such a pedestal imposes a distance between the well centre and the drilling
rig mast, which is e.g. suitable to receive a BOP.
[0035] In embodiments, the transportable base structure is furthermore provided with a skid
system to fine tune the position of the base structure adjacent a well centre. Such
a skid system, as is known per se in the art, may e.g. be provided at the outer ends
of the support beams of the H-shaped base structure.
[0036] In embodiments, the transport connection assembly comprises a transport beam, which
is connectable to the outer ends of the second set of support beams and which preferably
comprises a king pin to be connected to a fifth wheel of the vehicle. The connection
to the king pin enables steering movement of the base structure.
[0037] The second aspect of the invention further relates to a method for bringing a modular
transfigurable drilling rig system according to one or more of the preceding claims
from a field transport mode into an operational mode.
[0038] In embodiments, the method comprises the steps of:
- positioning the transportable base structure on the ground adjacent the well centre,
- disconnecting the second set of support beams from the transport connection assembly,
- removing the transport vehicle,
- positioning the lower section in a substantially horizontal position so that the foot
end of the mast is brought adjacent the base structure;
- connecting the lower section to the base structure;
- positioning the top section in a substantially horizontal position adjacent the lower
section;
- aligning and connecting the upper end of the lower section with a lower end of the
top section;
- operating the at least one drive assembly such that the drilling rig mast with the
top drive moves towards its vertical operational position.
[0039] It is noted that the top section of the drilling rig mast is the section that, when
the drilling rig is operational, is located on top of and vertically above the lower
section of the drilling rig mast. During road transport the top section and the lower
section of the drilling rig mast are typically in a horizontal position, i.e. do not
extend in a vertical direction but in a substantially horizontal direction.
[0040] In operational mode, the location of the transfigurable drilling rig system as a
whole is fixed, even though the system may allow for fine tuning of parts of the system
relative to the well center. When in the field transport mode, the location of the
transfigurable drilling rig can be changed using the transport wheels and the transport
connection system in combination with a vehicle.
[0041] As discussed above, in embodiments the transportable base structure further comprises
a cross beam adapted to be positioned on the ground near the well centre, to which
at least one set of support beams is connected in the operational mode. Advantageously,
the cross beam is of a foldable design, allowing the cross beam to be folded out in
the operational mode and folded in in the field transport mode such that the mutual
distance between the support beams is reduced. In such embodiments, the method further
comprises the step of folding out the cross beam, thereby increasing the mutual distance
between the support beams.
[0042] Optionally, the method further comprises the step of removing the transport wheels
from the first set of support beams. Alternatively, it is also conceivable that the
transport wheels remain accommodated by the first set of support beams.
[0043] Optionally, the method further comprises the step of removing the transport connection
assembly from the transport vehicle. It is also conceivable that the transport connection
assembly remains attached to the transport vehicle, to be ready for a further transport
of the modular drilling rig system.
[0044] A third aspect of the invention relates to a modular transfigurable drilling rig
composed of multiple components, which system is transfigurable between a transport
mode in which the components of the system are transportable by vehicles and an operational
mode in which the components are assembled to a drilling rig which is adapted to perform
drilling and/or wellbore related activities, e.g. drill into a well centre in the
ground, the drilling rig system comprising:
- a base structure adapted to be positioned in the operational mode on the ground;
- a drilling rig mast having a top end and a foot end, composed of multiple transportable
mast sections, said mast sections at least including a lower section comprising the
foot end of the mast, the lower section being connectable to the base structure, and
a top (crown) section comprising the top end of the mas;
- which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position; and
- drilling drawworks adapted to be mounted to the lower section of the drilling rig
mast in order to, in the operational mode, perform hoisting activities.
[0045] The drilling drawworks is an expensive and heavy piece of machinery, that is usually
positioned on the ground adjacent the drilling rig system.
[0046] It is therefor desirable to provide a modular transfigurable drilling rig system
that allows for the installation of drilling drawworks remote from the ground.
[0047] The invention proposes a transfigurable drilling rig system comprising a vehicle
transportable drilling drawworks ramp adapted to install the drawworks, the drilling
drawworks ramp comprising a sliding surface allowing the drilling drawworks to slide
over to the lower section of the drilling rig mast in the horizontal position,
wherein the sliding surface of the drilling drawworks ramp is positionable adjacent
a lower section of the mast in said substantially horizontal mast assembly position.
[0048] In embodiments is the drilling drawworks ramp provided with one or more alignment
and/or connection members, e.g. hooks, to align and/or connect the drilling drawworks
ramp with the lower mast section.
[0049] The thus achieved clearance of the ground in the drilling area is very advantageous
during drilling operations and enables a more efficient drilling process.
[0050] In embodiments, the drilling drawworks ramp further comprises a drilling drawworks
positioning assembly with a drive to slide the drilling drawworks over the sliding
surface and position the drilling drawworks onto the lower section of the drilling
rig mast. Alternatively, such a drive is separately provided.
[0051] In embodiments, the drilling drawworks positioning assembly comprises a winch driven
cable connectable to the drilling drawworks and adapted to slide the drilling drawworks
over the drilling drawworks ramp to install the drawworks. Alternative drive include
cylinders, chain drives, etc. etc.
[0052] In embodiments, the drilling rig system further comprises a drawworks subframe, which
is adapted to be mounted onto the lower mast section, and onto which the drilling
drawworks are adapted to be mounted in the substantially horizontal mast assembly
position. Such a subframe may facilitate on-site mounting. For example, upon displacement
of the drilling rig system on the field between multiple well centres, it is conceivable
that the drawworks subframe remains mounted to the lower mast section such that the
drilling drawworks can conveniently be mounted to the drilling drawworks subframe
after the displacement.
[0053] In embodiments, the drilling rig system further comprises at least one drive assembly
to move the drilling rig mast with the drilling drawworks between the substantially
horizontal mast assembly position and the vertical operational position.
[0054] In embodiments, the drilling rig mast comprises a lower section, a top section and
one or more intermediate mast sections. Preferably mast sections have a U-shaped horizontal
cross section with a left-hand mast wall, a rear mast wall, and a right-hand mast
wall, and with an open front. The invention also relates to a method for bringing
a modular transfigurable drilling rig system composed of multiple components from
a transport mode in which the components of the system are transportable by vehicles
into an operational mode in which the components are assembled to a drilling rig which
is adapted to perform drilling and/or wellbore related activities, e.g. drill into
a well centre in the ground, the drilling rig system comprising:
- a base structure adapted to be positioned in the operational mode on the ground;
- a drilling rig mast having a top end and a foot end, composed of multiple transportable
mast sections, said mast sections at least including a lower section comprising the
foot end of the mast, the lower section being connectable to the base structure, and
a top (crown) section comprising the top end of the mast;
- which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position, e.g. vertically above a well center; and
- drilling drawworks adapted to be mounted to the lower section of the drilling rig
mast in order to, in the operational mode, perform hoisting activities;
wherein the method comprises the steps of:
- positioning the base structure on the ground adjacent the well centre,
- positioning the lower mast section so that the foot end of the lower mast section
is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- supplying the drilling drawworks;
- positioning and mounting the drilling drawworks onto the lower section of the drilling
mast prior to moving the drilling rig mast with the drilling drawworks moves towards
its vertical operational position.
[0055] The invention further relates to a method for bringing a modular transfigurable drilling
rig system from a transport mode into an operational mode, wherein the method comprises
the steps of:
- positioning the base structure on the ground adjacent the well centre,
- positioning the lower mast section so that the foot end of the lower mast section
is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- supplying the drilling drawworks ramp, preferably by a vehicle, and positioning the
drilling drawworks ramp adjacent the lower section,
- supplying, preferably by means of a vehicle, the drilling drawworks to the drilling
drawworks ramp;
- sliding the drilling drawworks over the sliding surface to the lower section of the
drilling mast;
- mounting the drilling drawworks to the lower section;
- removing the drilling drawworks ramp.
[0056] In embodiments, the method further comprises the step of installing a drawworks subframe
onto the substantially horizontal lower mast section, prior to the positioning and
mounting of the drilling drawworks.
[0057] It will be appreciated that all aspects of the invention can be readily combined
with one or more of the other aspects of the invention as described herein and/or
with one or more optional and/or preferred features as described herein primarily
with reference to said one or more other aspects of the invention.
[0058] For example, in an embodiment according to the invention, the vehicle transportable
top drive unit installation device of the first aspect of the invention is configured
as a drilling drawworks ramp according to the third aspect of the invention, such
that the top drive unit installation device can also be used for installing the drawworks
onto the lower section of the drilling rig mast and vice versa.
[0059] The invention can be summarized according to one or more of the following clauses:
- 1. Modular transfigurable drilling rig system composed of multiple components, which
system is transfigurable between a transport mode in which the components of the system
are transportable by vehicles and an operational mode in which the components are
assembled to a drilling rig which is adapted to perform drilling and/or wellbore related
activities, e.g. drill into a well centre in the ground, the drilling rig system comprising:
- a base structure adapted to be positioned in the operational mode on the ground;
- a drilling rig mast having a top end and a foot end, composed of multiple transportable
mast sections, said mast sections at least including a lower mast section comprising
the foot end of the mast, the lower section being connectable to the base structure,
and a top mast section comprising the top end of the mast, and preferably one or more
intermediate mast sections ,
- which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position, e.g. vertically above a well center;
- a top drive unit adapted to be positioned in the drilling rig mast so as to perform
drilling activities;
wherein the drilling rig system further comprises a temporary removable vehicle transportable
top drive unit installation device that comprises a frame that is adapted to receive
the top drive unit so as to transport the installation device with the top drive unit
therein by a vehicle, wherein the frame of the installation device is positionable
in line with an end of a mast section of the mast in said substantially horizontal
mast assembly position, e.g. of an intermediate mast section of the mast prior to
assembly of the top mast section, wherein, for example, the frame is provided with
one or more alignment and/or connection members, e.g. hooks , to align and/or connect
the frame with the respective mast section, so as to be able to transfer the top drive
unit from the frame of vehicle transportable top drive unit installation device into
the drilling rig mast in the substantially horizontal mast assembly position thereof,
before removing the frame of the vehicle transportable top drive unit installation
device, prior to moving the drilling rig mast with the top drive unit towards its
vertical operational position.
- 2. Drilling rig system according to clause 1, wherein the temporary removable installation
device comprises a top drive unit translation assembly with a translation drive to
transfer, e.g. slide, the top drive unit from the frame of the installation device
into the drilling rig mast in the substantially horizontal mast assembly position
thereof.
- 3. Drilling rig system according to clause 2, wherein the translation drive comprises
a winch and a winch driven cable connectable to the top drive unit and adapted to
transfer, e.g. slide, the top drive unit into the mast in its substantially horizontal
assembly position.
- 4. Drilling rig system according to any of clauses 1-3, wherein the frame comprises
one or more rails that are aligned with said one or more rails of the mast when the
frame of the temporary removable installation device is positioned in line with an
end of a mast section of the mast in said substantially horizontal mast assembly position,
and wherein the top drive unit comprises one or more rail followers that are engaged
with the one or more rails of the frame prior to said transfer into the mast and then
are engaged with said one or more rails of the mast upon transfer into the mast.
- 5. Drilling rig system according to any of clauses 1 - 4, wherein the mast is adapted
to be - in its substantially horizontal assembly position - with its open front facing
down, e.g. said open front at a height of less than 1 metre above the ground.
- 6. Drilling rig system according to any of clauses 1 - 5, wherein the mast sections
comprise left-hand and right-hand vertical front posts and rear corner posts, with
each front post being connected by bracings to a respective rear corner post to form
the respective side wall of the mast and said rear corner posts being connected to
each other by bracings to form the respective rear wall of the mast, and wherein,
preferably, a vertical rail is fixed to each of the front posts and the top drive
unit is guided along said vertical rails.
- 7. Drilling rig system according to any of clauses 1 - 6, wherein the top mast section
comprises a crown block assembly with cable sheaves mounted to the top mast section
and a travelling block assembly with cable sheaves, wherein, preferably, one or more
cables are pre-reeved over said crown block and travelling block assembly.
- 8. Drilling rig system according to any of clauses 1 - 7, further comprising at least
one drive assembly to move the drilling rig mast with the top drive between the substantially
horizontal mast assembly position and the vertical operational position.
- 9. Drilling rig system according to any of clauses 1 - 8, wherein an intermediate
mast section of the mast comprises a drag chain with one or more electrical and/or
hydraulic lines connectable to the top drive unit.
- 10. Method for bringing a modular transfigurable drilling rig system according to
any of clauses 1 - 9 into operational mode, said method comprising:
- placing the base structure on the ground;
- positioning the lower mast section in a generally horizontal position thereof such
that the foot end of the lower mast section is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- positioning one or more further drilling rig mast sections in substantially horizontal
position thereof in line with the lower mast section and interconnecting said mast
sections;
wherein the method further comprises:
- positioning the vehicle transportable top drive unit installation device in line with
the end of a mast section of the mast in said substantially horizontal mast assembly
position, e.g. of an intermediate mast section of the mast prior to assembly of the
top mast section;
- transferring, e.g. sliding, the top drive unit from the frame of the installation
device into the drilling rig mast in the substantially horizontal mast assembly position
thereof;
- removing the frame of the temporary removable vehicle transportable top drive unit
installation device , prior to moving the drilling rig mast with the top drive unit
towards its vertical operational position.
- 11. Method according to clause 10, for bringing a drilling rig system according to
clause 2 into operational mode, further comprising the step of operating the translation
drive of the top drive unit translation assembly to transfer, e.g. slide, the top
drive unit from the frame of the installation device into the drilling rig mast in
the substantially horizontal mast assembly position thereof.
- 12. Method according to clause 11, wherein the translation drive comprises a winch
and a winch driven cable connectable to the top drive unit, and wherein the winch
is operated to transfer, e.g. slide, the top drive unit into the mast in its substantially
horizontal assembly position.
- 13. Method according to any of clauses 10-12, wherein the frame comprises one or more
rails that are aligned with said one or more rails of the mast when the frame of the
installation device is positioned in line with an end of a mast section of the mast
in said substantially horizontal mast assembly position, and wherein the top drive
unit comprises one or more rail followers that are engaged with the one or more rails
of the frame prior to said transfer into the mast and then are engaged with said one
or more rails of the mast upon transfer into the mast.
- 14. Method according to any of clauses 10 - 13, wherein the mast is assembled - in
its substantially horizontal assembly position - with its open front facing down,
e.g. said open front at a height of less than 1 metre above the ground.
- 15. Method according to any of clauses 10 - 14, wherein the top drive unit installation
device is offloaded from a road vehicle and positioned in line with and connected
to the respective mast section, and wherein the top drive unit is subsequently transferred
into the mast.
- 16. Method according to any of clauses 10 - 15, wherein the vehicle transportable
top drive unit installation device is positioned in line with the end of an intermediate
mast section of the mast in said substantially horizontal mast assembly position,
and wherein the top drive unit is then transferred into said intermediate mast section,
and wherein the frame of the installation device is then removed, and wherein subsequently
the top mast section is positioned in line with the already assembled part of the
mast and connected thereto.
- 17. Method according to any of clauses 10- 16, wherein the top mast section comprises
a crown block assembly with cable sheaves mounted to the top mast section and a travelling
block assembly with cable sheaves, wherein, preferably, one or more cables are pre-reeved
over said crown block and travelling block assembly,
and wherein the method comprises the step of connecting the travelling block assembly
to the top drive unit that has been transferred into an adjoining intermediate mast
section, e.g. wherein the travelling block assembly comprises a hook that is engageable
with the top drive unit.
- 18. Modular transfigurable drilling rig system composed of multiple components, which
system is transfigurable between a field transport mode in which components of the
system are transportable on the field by vehicles between multiple well centers, and
an operational mode in which the components are assembled to a drilling rig which
is adapted to drill into a well centre in the ground of the field, the system comprising:
- a drilling rig mast having a top end and a foot end , which is movable between a substantially
horizontal mast assembly position and an operational position substantially vertically
above the well centre, the drilling rig mast including:
∘ a lower section comprising the foot end of the mast, the lower section being connectable
to a base structure , and
∘ a top section comprising the top end of the mast and a top drive,
- at least one drive assembly to move the drilling rig mast with the top drive between
the substantially horizontal mast assembly position and the vertical operational position,
- a base structure adapted to be positioned in the operational mode in a H shape on
the ground adjacent a well centre to support the drilling rig mast thereon, which
base structure is adapted to be transported by a vehicle , the H-shaped base structure
comprising an assembly of interconnected parts, including:
∘ a first set of support beams adapted to be positioned on the ground with the well
center there between, the first set of beams extending in a first direction , which
support beams are adapted to accommodate transport wheels , at least in the field
transport mode; and
∘ a second set of support beams adapted to be placed on the ground and extending in
a second direction opposite to the first direction ,
- transport wheels , adapted to be accommodated by the first set of support beams ;
- a transport connection assembly which, in the field transport mode of the system,
is adapted to be provided between the second set of support beams the and connected
to the vehicle in order to transport the base structure as a whole.
- 19. System according to clause 18, wherein the transportable base structure further
comprises a cross beam , adapted to be positioned on the ground near the well centre,
to which at least one of the first and/or second set of support beams is connected
in the operational mode, wherein preferably the cross beam is of a foldable design,
allowing the cross beam to be folded out in the operational mode and folded in in
the field transport mode such that the mutual distance between the support beams is
reduced.
- 20. System according to clause 18, wherein the lower section further comprises drilling
drawworks .
- 21. System according to clause 18, wherein the lower section further comprises a pedestal,
adapted to support the drilling rig mast above the well centre in the operational
mode.
- 22. System according to clause 18, wherein the transportable base structure is furthermore
provided with a skid system to fine tune the position of the base structure adjacent
a well centre
- 23. System according to clause 18, wherein the transport connection assembly comprises
a transport beam, which is connectable to the outer ends of the second set of support
beams and which preferably comprises a king pin to be connected to a fifth wheel of
the vehicle .
- 24. Method for bringing a modular transfigurable drilling rig system according to
one or more of the preceding clauses 18-23 from a field transport mode into an operational
mode.
- 25. Method according to clause 24, comprising the steps of:
- positioning the transportable base structure on the ground adjacent the well centre;
- disconnecting the second set of support beams from the transport connection assembly;
- removing the transport vehicle;
- positioning the lower section in a substantially horizontal position so that the foot
end of the mast is brought adjacent the base structure;
- connecting the lower section to the base structure;
- positioning the top section in a substantially horizontal position adjacent the lower
section;
- aligning and connecting the upper end of the lower section with a lower end of the
top section;
- operating the at least one drive assembly such that the drilling rig mast with the
top drive moves towards its vertical operational position.
- 26. Method according to clauses 19 and 24 or 25, further comprising the step of folding
out the cross beam, thereby increasing the mutual distance between the support beams.
- 27. Method according to clause 24 or 25, further comprising the step of removing the
transport wheels from the first set of support beams.
- 28. Method according to clause 24 or 25, further comprising the step of removing the
transport connection assembly from the transport vehicle.
- 29. Modular transfigurable drilling rig system composed of multiple components, which
system is transfigurable between a transport mode in which the components of the system
are transportable by vehicles and an operational mode in which the components are
assembled to a drilling rig which is adapted to perform drilling and/or wellbore related
activities, the drilling rig system comprising:
- a base structure adapted to be positioned in the operational mode on the ground;
- a drilling rig mast having a top end and a foot end, composed of multiple transportable
mast sections, said mast sections at least including a lower section comprising the
foot end of the mast, the lower section being connectable to the base structure, and
a top section comprising the top end of the mast;
- which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position; and
- drilling drawworks adapted to be mounted to the lower section of the drilling rig
mast in order to, in the operational mode, perform hoisting activities;
- a vehicle transportable drilling drawworks ramp adapted to install the drawworks ,
the drilling drawworks ramp comprising a sliding surface allowing the drilling drawworks
to slide over to the lower section of the drilling rig mast in the horizontal position;
wherein the sliding surface of the drilling drawworks ramp is positionable adjacent
a lower section of the mast in said substantially horizontal mast assembly position.
- 30. Drilling rig system according to clause 29, wherein the drilling drawworks ramp
further comprises a drilling drawworks positioning assembly with a drive to slide
the drilling drawworks over the sliding surface and position the drilling drawworks
onto the lower section of the drilling rig mast.
- 31. Drilling rig system according to clause 30, wherein the drilling drawworks positioning
assembly comprises a winch and a winch driven cable connectable to the drilling drawworks
and adapted to slide the drilling drawworks over the drilling drawworks ramp to install
the drawworks.
- 32. Drilling rig system according to any of clauses 29 - 31, further comprising a
drawworks subframe , which is adapted to be mounted onto the lower mast section, and
onto which the drilling drawworks are adapted to be mounted in the substantially horizontal
mast assembly position.
- 33. Drilling rig system according to any of clauses 29 - 32, further comprising at
least one drive assembly to move the drilling rig mast with the drilling drawworks
between the substantially horizontal mast assembly position and the vertical operational
position.
- 34. Method for bringing a modular transfigurable drilling rig system composed of multiple
components from a transport mode in which the components of the system are transportable
by vehicles into an operational mode in which the components are assembled to a drilling
rig which is adapted to perform drilling and/or wellbore related activities, the drilling
rig system comprising:
- a base structure adapted to be positioned in the operational mode on the ground;
- a drilling rig mast having a top end and a foot end, composed of multiple transportable
mast sections, said mast sections at least including a lower section comprising the
foot end of the mast, the lower section being connectable to the base structure, and
a top section comprising the top end of the mast;
- which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position; and
- drilling drawworks adapted to be mounted to the lower section of the drilling rig
mast in order to, in the operational mode, perform hoisting activities;
wherein the method comprises the steps of:
- placing the base structure on the ground;
- positioning the lower mast section in a generally horizontal position thereof such
that the foot end of the lower mast section is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- supplying the drilling drawworks;
- positioning and mounting the drilling drawworks onto the lower section of the drilling
mast prior to moving the drilling rig mast with the drilling drawworks towards its
vertical operational position.
- 35. Method for bringing a modular transfigurable drilling rig system according to
one or more of the preceding clauses 29 - 33 from a transport mode into an operational
mode according to clause 34, wherein the method comprises the steps of:
- supplying the drilling drawworks ramp, preferably by a vehicle, and positioning the
drilling drawworks ramp adjacent the lower section;
- supplying, preferably by means of a vehicle, the drilling drawworks to the drilling
drawworks ramp;
- sliding the drilling drawworks over the sliding surface to the lower section of the
drilling mast;
- mounting the drilling drawworks to the lower section;
- removing the drilling drawworks ramp.
- 36. Method according to clause 34 or 35, further comprising the step of installing
a drawworks subframe onto the lower mast section prior to the positioning and mounting
of the drilling drawworks.
[0060] The invention is further described in the claims and explained here below in relation
to the drawings, in which:
- Figs. 1A,1B, 1C
- show in top view the base structure of a modular transfigurable drilling rig system
transported by a vehicle according to a second aspect of the present invention in
the field transport mode, and the vehicle without the base structure;
- Figs. 2A, 2B
- show in side view the base structure and lower section a modular transfigurable drilling
rig according to the second aspect of the invention in the field transport mode;
- Figs. 3A, 3B, 3C
- show in side view the base structure and lower section a modular transfigurable drilling
rig according to the second aspect of the invention in the field transport mode;
- Figs. 4a - d
- illustrate the transfer of a top drive unit into the partly assembled mast of an exemplary
modular transfigurable drilling rig system of the invention,
- Figs. 5a, 5b
- illustrate the completion of the mast of figures 4a-d with a top mast section,
- Figs. 5c, d
- illustrate the hooking of the travelling block onto the top drive unit,
- Figs. 6A, 6B
- show in side view a drilling drawworks ramp according to a third aspect of the present
invention,
- Figs. 7A, 7B, 7C
- show in side view the installation of drilling drawworks via a drilling drawworks
ramp according to a third aspect of the present invention,
- Figs. 8A, 8B
- show in different side views a lower mast section prior to be moved to the vertical
operational position, onto which drilling drawworks are positioned.
[0061] In figs. 1-3 an embodiment of the invention is shown in the field transport mode
in which components of the system are transportable on the field by vehicles between
multiple well centers.
[0062] In particular, in figs. 1A-1B the transport of the base structure by a vehicle is
shown, in figs. 2A-2B the transport of the lower section of the drilling rig mast
and in figs. 3A-3C the transport of the top section of the drilling rig mast.
[0063] In fig. 1A, a base structure 20 is shown in top view, which is in fig. 1A positioned
on the ground adjacent a well centre W, to support a drilling rig mast thereon. In
fig. 1A, the base structure is transported by a vehicle 10. In fig. 1C the vehicle
10 is shown without the base structure.
[0064] The base structure 20 comprises a first set of support beams 23a, 23b, which are
positioned on the ground with the well center W there between. The first set of beams
23a, 23b extend in a first direction D1. In the shown field transport mode, the support
beams 23a, 23b accommodate transport wheels 25a, 25 respectively. The transport wheels
25a, 25b are possibly removed in the operational mode. However, it is also conceivable
that the wheels remain connected to the support beams for further within field movements.
[0065] The base structure further comprises a second set of support beams 22a, 22b, placed
on the ground and extending in a second direction D2 opposite to the first direction
D1, such that the base structure 20 is formed in a H shape in the transport mode shown
in fig. 1A and in the operational mode.
[0066] In the shown field transport mode of figs. 1A and 1B, a transport connection assembly
15 is provided between the vehicle 10 and the second set of support beams 22a, 22b
in order to transport the base structure 20 as a whole.
[0067] In the shown embodiment, the transport connection assembly 15 comprises a transport
beam, which is in figs. 1A and 1B connected to the outer ends of the second set of
support beams 22a, 22b and to a king pin 11 of the vehicle 10. In fig. 1C, it is visible
that the transport beam 15 is connected to the vehicle 10. Optionally, the transport
beam is removed, but it is also conceivable that the transport beam remains connected
to the vehicle for further within field moves.
[0068] In the shown embodiment, the transportable base structure 20 in the operational mode
further comprises a cross beam 21 adapted to be positioned on the ground near the
well centre W. In the shown embodiment, the second set of support beams 22a, 22b is
connected to the cross beam. The first set of support beams 23a, 23b is connected
to the second set of support beams. It is also conceivable that only the first set
of support beams is connected to the cross beam 21, and the second set of support
beams is connected to the first set. Yet alternatively, it is conceivable that both
the first and the second set of support beams are connected to opposed sides of the
cross beam.
[0069] It is conceivable that the base structure 20 is transportable as a whole with the
cross beam and connected support beams in the H-shape as shown in fig. 1B. However,
possibly a decreased width is required. To this end, advantageously the cross beam
21 is of a foldable design, allowing the cross beam to be folded out in the operational
mode (as visible in fig. 1B) and folded in in the field transport mode (as visible
in fig. 1A) such that the mutual distance between the support beams (22a and 22b,
and 23a and 23b respectively) is reduced.
[0070] In the shown embodiment, the transportable base structure 20, in particular the first
set of support beams 23a, 23b, is furthermore provided with a skid system 24a, 24b
to fine tune the position of the base structure 20 adjacent a well centre W.
[0071] In fig. 2A, the base structure 20 is shown in a side view, with the transport vehicle
removed. The base structure is provided with a drilling rig mast receptacle 26 to
allow the connection of the drilling rig mast to the base structure. In the shown
embodiment, the drilling rig mast receptacle is provided on the cross beam 21.
[0072] At the right-hand side of fig. 2A, a vehicle 30 with a lower section 40 of the drilling
rig mast is shown. The lower section 40 comprises a foot end 41 of the drilling rig
mast. In the shown embodiment, the lower section 40 further comprises drilling drawworks
42. In the shown embodiment, the lower section 40 further comprises a pedestal 43,
adapted to support the drilling rig mast above the well centre in the operational
mode.
[0073] In fig. 2B, the lower section has been positioned in a substantially horizontal position
adjacent the base structure, allowing the connection of the lower section 40, in particular
a connection hole 43a provided at the outer end of the pedestal 43, to the drilling
rig mast receptacle 26 to the base structure 20.
[0074] In fig. 3A, a drive assembly 45 is connected to the lower section 40 of the drilling
rig mast. In the shown embodiment, the drive assembly 45 comprises two hydraulic cylinders,
mounted between the second set of support beams 22a, 22b of the base structure 20
and the pedestal 43 at the foot end 41 of the mast. In fig. 3A, the drive assembly
45 has moved the lower section upwards.
[0075] In fig. 3B, a transport vehicle 30 with a top section 50 of the drilling rig mast
is shown, which is positioned in a substantially horizontal position adjacent the
lower section 40. The top section 50 comprises the top end of the mast 51 and a top
drive 52. In fig. 3C, the alignment and connection of the upper end of the lower section
40 with a lower end of the top section 50 is visible.
[0076] From the position of fig. 3C, the drive assembly 45 may be operated to move the drilling
rig mast with the top drive 52 between the substantially horizontal mast assembly
position, as visible in fig. 3C, and a vertical operational position.
[0077] In figures 4a - d the transfer of a top drive unit into the partly assembled mast
of an exemplary modular transfigurable drilling rig system of the invention is illustrated.
[0078] Generally the drilling rig system according to the invention is composed of multiple
components, and the system is transfigurable between a transport mode in which the
components of the system are transportable by vehicles and an operational mode in
which the components are assembled to a drilling rig which is adapted to perform drilling
and/or wellbore related activities, e.g. drill into a well centre in the ground.
[0079] The drilling rig system comprises a base structure 100 that is adapted to be positioned
in the operational mode on the ground, for example the base structure is embodied
as described with reference to figures 1 - 3;
[0080] The drilling rig system comprises a drilling rig mast 110 having a top end and a
foot end.
[0081] The mast 110 is composed of multiple transportable mast sections, including a lower
mast section 111 comprising the foot end of the mast, the lower section being connectable
to the base structure, and a top mast section 113 comprising the top end of the mast.
Here the mast also comprises an intermediate mast section 112.
[0082] The mast sections 111, 112, 113 have a U-shaped horizontal cross section with a left-hand
mast wall, a rear mast wall, and a right-hand mast wall, and with an open front that
is facing downwards in the illustrations of figures 4a-d. The open front end allows
for the introduction of drilling tubulars, e.g. drill pipes, into the mast in the
firing line below the top drive unit.
[0083] The mast sections 111, 112, 113, are provided with one or more vertical rails 114
adapted to guide a top drive unit 120.
[0084] In more detail the mast sections 111, 112, 113 comprise left-hand and right-hand
vertical front posts and rear corner posts, with each front post being connected by
bracings to a respective rear corner post to form the respective side wall of the
mast and said rear corner posts being connected to each other by bracings to form
the respective rear wall of the mast.
[0085] A vertical rails 114 is fixed to each of the front posts and the top drive unit 120
is guided along said vertical rails 114. Other arrangements of one or more vertical
rails in the mast sections are also envisaged.
[0086] The drilling rig mast, once assembled, is movable between the substantially horizontal
mast assembly position, wherein the mast is assembled by interconnection of said multiple
mast sections in generally horizontal orientation and, in the operational mode, a
vertical operational position, e.g. vertically above a well center.
[0087] The top drive unit 120 is adapted to be positioned in the drilling rig mast 110 so
as to be guided by said one or more vertical rails 114 allowing for vertical motion
of the top drive unit relative to the mast to perform drilling activities.
[0088] The drilling rig system further comprises a vehicle transportable top drive unit
installation device 130 that comprises a frame 135 that is adapted to receive the
top drive unit 120 so as to transport the installation device with the top drive unit
therein by a vehicle 150.
[0089] The frame 135 of the installation device 130 is positionable in line with an end
of a mast section of the mast in said substantially horizontal mast assembly position,
here the intermediate mast section 112 of the mast prior to assembly of the top mast
section 113.
[0090] In this example the frame 135 is provided with one or more alignment and/or connection
members, here hooks 136, to align and/or connect the frame with the respective mast
section 111.
[0091] The installation device 130 further, as preferred feature, comprises a top drive
unit translation assembly with a translation drive to transfer, e.g. slide, the top
drive unit 120 from the frame of the installation device into the drilling rig mast
in the substantially horizontal mast assembly position thereof, e.g. with one or more
rail followers 122 of the top drive unit 120 being engaged with said one or more rails
114 of the mast.
[0092] In this example the frame 135 comprises one or more rails (not shown) that are aligned
with said one or more rails 114 of the mast when the frame 135 of the installation
device is positioned in line with an end of a mast section 111 of the mast in said
substantially horizontal mast assembly position.
[0093] The rail followers that are engaged with the one or more rails of the frame prior
to said transfer into the mast are then engaged with said one or more rails 114 of
the mast upon transfer into the mast.
[0094] In this example, the translation drive comprises a winch 137 and a winch driven cable
138 connectable to the top drive unit 120 and adapted to transfer, e.g. slide, the
top drive unit into the mast in its substantially horizontal assembly position.
[0095] As can be seen the mast is facing - in its substantially horizontal assembly position
- with its open front facing down, e.g. said open front at a height of less than 1
metre above the ground, so generally below the bed of the vehicle 150.
[0096] The top mast section 113 comprises a crown block assembly 115 with cable sheaves
mounted to the top mast section and a travelling block assembly 116 with cable sheaves.
As preferred, one or more cables 117 are pre-reeved over said crown block and travelling
block assemblies.
[0097] The intermediate mast section 112 of the mast comprises a drag chain 112a with one
or more electrical and/or hydraulic lines connectable to the top drive unit 120.
[0098] As the skilled person will already appreciate from the illustrations in figures 4a
-d, 5a, 5b, the method for bringing the modular transfigurable drilling rig system
into operational mode involves inter alia the steps of:
- placing the base structure 100 on the ground,
- positioning the lower mast section 111 in generally horizontal position thereof such
that the foot end of the lower mast section is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- positioning the intermediate mast section 112 in substantially horizontal position
thereof in line with the lower mast section 111 and interconnecting said mast sections.
[0099] The method further comprises the steps of:
- positioning the vehicle transportable top drive unit installation device 130 in line
with the end of the intermediate mast section 112 in said substantially horizontal
mast assembly position,
- operating the translation drive, here winch 137, of the top drive unit translation
assembly and transferring, here sliding, the top drive unit 120 from the frame 135
of the installation device into the drilling rig mast in the substantially horizontal
mast assembly position thereof. Here with the one or more rail followers 122 of the
top drive unit 120 engaging with said one or more rails 114 of the mast once they
disengage from the one or more rails 136 of the frame 135.
[0100] As illustrated it is preferred that the mast is assembled - in its substantially
horizontal assembly position - with its open front facing down, here said open front
at a height of less than 1 metre above the ground. It is also preferred to place the
device 130 on the ground to effect the discussed transfer, which involves offloading
the device 130 from the road vehicle 150, for example in the manner depicted in figures
4a, b. Other offloading approaches are also possible, however in the depicted approach
the device (whilst resting on the vehicle bed) is connected to the mast end (e.g.
the mast end being raised slightly) and then pulled from the vehicle bed.
[0101] So, it is illustrated here that the top drive unit installation device is offloaded
from a road vehicle and positioned in line with and connected to the respective mast
section, and the top drive unit is subsequently transferred into the mast.
[0102] It is illustrated that the vehicle transportable top drive unit installation device
130 is positioned in line with the end of an intermediate mast section 112 of the
mast in said substantially horizontal mast assembly position, and that the top drive
unit 120 is then transferred into said intermediate mast section 111. Then the frame
135 of the installation device is removed, and subsequently the top mast section 113
is positioned in line with the already assembled part of the mast and connected thereto
as illustrated in figures 5a, b.
[0103] It is illustrated in figures 5c, d how the connection between the travelling block
assembly 116 and the top drive unit 120 that has already been transferred into an
adjoining intermediate mast section can be made. In this example the travelling block
assembly comprises a hook 116a that is engageable with the top drive unit, e.g. by
allowing the hooked end to tilt downward over a corresponding bail of the top drive
unit.
[0104] Once the mast is completely assembled the mast is raised or erected into its vertical
operation position, e.g. by means of one or more hydraulic actuators 160 between the
base structure and the mast or by some other means.
[0105] In figs. 6-8 the installation of drilling drawworks onto an at least partly assembled
mast of an exemplary modular transfigurable drilling rig system of a third aspect
of the invention is illustrated.
[0106] Similar to the embodiment of figs. 4-5, the drilling rig system of the invention
is composed of multiple components, and the system is transfigurable between a transport
mode in which the components of the system are transportable by vehicles and an operational
mode in which the components are assembled to a drilling rig which is adapted to perform
drilling and/or wellbore related activities, e.g. drill into a well centre in the
ground.
[0107] The drilling rig system comprises a base structure 210 adapted to be positioned in
the operational mode on the ground, for example the base structure is embodied as
described with reference to figs. 1-3 or 4-5.
[0108] The drilling rig system further comprises a drilling rig mast having a top end (not
shown) and a foot end. The mast is composed of multiple transportable mast sections,
including a lower section 240 comprising the foot end of the mast, the lower section
being connectable to the base structure. Possibly the mast is embodied as described
with reference to figs. 4 and 5, further comprising a top (crown) section comprising
the top end of the mast, and an intermediate mast section.
[0109] The shown mast section 240 has a U-shaped horizontal cross section with a left-hand
mast wall, a rear mast wall, and a right-hand mast wall, and with an open front.
[0110] The drilling rig mast, once assembled, is movable between a substantially horizontal
mast assembly position, wherein the mast is assembled by interconnection of said multiple
mast sections in generally horizontal orientation and, in the operational mode, a
vertical operational position, e.g. vertically above a well center.
[0111] Drilling drawworks 242 are adapted to be mounted to the lower section 240 of the
drilling rig mast in order to, in the operational mode, perform hoisting activities.
[0112] The drilling rig system further comprises a vehicle transportable drilling drawworks
ramp 200 adapted to install the drawworks 242, the drilling drawworks ramp comprising
a sliding surface 201 allowing the drilling drawworks to slide over to the lower section
of the drilling rig mast in the horizontal position. The drilling drawworks ramp 200
of the shown embodiment is the same as the vehicle transportable top drive unit installation
device 130 of figs. 4 and 5.
[0113] The sliding surface of the drilling drawworks ramp is positionable adjacent a lower
section of the mast in said substantially horizontal mast assembly position.
[0114] In this example, the drilling drawworks ramp 200 is provided with one or more alignment
and/or connection members 208, e.g. hooks, to align and/or connect the drilling drawworks
ramp with corresponding connection members 209 provided at the lower mast section
240.
[0115] The drilling drawworks ramp 200 further, as a preferred feature, comprises a drilling
drawworks positioning assembly 202, 203 with a drive 205 to slide the drilling drawworks
242 over the sliding surface and position the drilling drawworks onto the lower section
of the drilling rig mast.
[0116] In this example, the drilling drawworks positioning assembly comprises a winch 205
and a winch driven cable 202 connectable to the drilling drawworks and adapted to
slide the drilling drawworks over the drilling drawworks ramp to install the drawworks.
It is noted that where the same drilling drawworks ramp 200 is used as a top drive
unit translation assembly, the same winch and winch driven cable may be applied.
[0117] In the shown embodiment, a drawworks subframe 245 is mounted onto the lower mast
section 240. As visible in figs. 7a-7c, the drilling drawworks are adapted to be mounted
onto the drawworks subframe 245 in the substantially horizontal mast assembly position.
[0118] In embodiments, not shown, further a drive assembly is provided to move the drilling
rig mast with the drilling drawworks between the substantially horizontal mast assembly
position and the vertical operational position.
[0119] As the skilled person will already appreciate from the illustrations in figs. 6-8,
the method for bringing a modular transfigurable drilling rig system into an operational
mode involves inter alia the steps of:
- positioning the base structure 210 on the ground,
- positioning the lower mast section 240 so that the foot end of the lower mast section
is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- supplying the drilling drawworks 242;
- positioning and mounting the drilling drawworks onto the lower section of the drilling
mast;
- moving the drilling rig mast with the drilling drawworks towards its vertical operational
position.
[0120] Advantageoulsy, the method includes the use of the drilling drawworks ramp 200, and
the method includes the steps of:
- positioning the base structure on the ground,
- positioning the lower mast section so that the foot end of the lower mast section
is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- supplying the drilling drawworks ramp 200, preferably by a vehicle, and positioning
the drilling drawworks ramp adjacent the lower section,
- supplying, preferably by means of a vehicle, the drilling drawworks 242 to the drilling
drawworks ramp;
- sliding the drilling drawworks over the sliding surface to the lower section of the
drilling mast;
- mounting the drilling drawworks to the lower section;
- removing the drilling drawworks ramp.
[0121] Possibly the method further comprises the step of installing a drawworks subframe
245 onto the substantially horizontal lower mast section, as has already been installed
in fig. 6a.
[0122] So, it is illustrated here that the drilling drawworks is mounted to the lower mast
section, possibly via a drawworks subframe, prior to the erection of the transfigurable
drilling rig system.
[0123] It is illustrated that advantageously a drilling drawworks ramp 200 is used, which
is positioned, here by a vehicle 230, in line with and connected to the lower mast
section 240 (fig. 6A), via connection means 208, 209 (fig. 6B). Drilling drawworks
are provided to the ramp 200, here by a vehicle 233 (Fig. 7A), possibly the same vehicle
as provided the drilling drawworks ramp 200. The drilling drawworks are allowed to
slide over the sliding surface 201 of the drilling drawworks ramp 200 onto the lower
mast section 240, in particular onto the drawworks subframe 245 mounted onto the lower
mast section 240 (Fig. 7B). Here, sliding occurs by operating the winch 205 actuating
the winch driven cable 202. Then the drilling drawworks ramp is removed, as illustrated
in fig. 7C. Subsequently the other mast sections may be connected to the lower mast
section, similar to what is shown in figs. 3A-3C or 5a, 5b.
1. Modular transfigurable drilling rig system composed of multiple components, which
system is transfigurable between a transport mode in which the components of the system
are transportable by vehicles and an operational mode in which the components are
assembled to a drilling rig which is adapted to perform drilling and/or wellbore related
activities, e.g. drill into a well centre in the ground, the drilling rig system comprising:
- a base structure (100) adapted to be positioned in the operational mode on the ground;
- a drilling rig mast (110) having a top end and a foot end, composed of multiple
transportable mast sections, said mast sections at least including a lower mast section
(111) comprising the foot end of the mast, the lower section being connectable to
the base structure, and a top mast section (113) comprising the top end of the mast,
and preferably one or more intermediate mast sections (112),
- which drilling rig mast is movable between a substantially horizontal mast assembly
position, wherein the mast is assembled by interconnection of said multiple mast sections
in generally horizontal orientation and, in the operational mode, a vertical operational
position, e.g. vertically above a well center;
- a top drive unit adapted to be positioned in the drilling rig mast so as to perform
drilling activities;
wherein the drilling rig system further comprises a top drive unit installation device
(130) that is temporary removable and that is transportable by a vehicle, which top
drive unit installation device comprises a frame (135) that is adapted to receive
the top drive unit so as to transport the top drive unit installation device with
the top drive unit therein by a vehicle,
wherein the frame of the top drive unit installation device is positionable in line
with an end of a mast section of the mast in said substantially horizontal mast assembly
position, e.g. of an intermediate mast section of the mast prior to assembly of the
top mast section, wherein, for example, the frame of the top drive unit installation
device is provided with one or more alignment and/or connection members, e.g. hooks
(136), to align and/or connect the frame of the top drive unit installation device
with the respective mast section, so as to be able to transfer the top drive unit
from the frame of the top drive unit installation device (130) into the drilling rig
mast in the substantially horizontal mast assembly position thereof, before removing
the frame of the top drive unit installation device, prior to moving the drilling
rig mast with the top drive unit towards its vertical operational position.
2. Drilling rig system according to claim 1, wherein the temporary removable installation
device comprises a top drive unit translation assembly with a translation drive to
transfer, e.g. slide, the top drive unit from the frame of the installation device
into the drilling rig mast in the substantially horizontal mast assembly position
thereof, wherein preferably the translation drive comprises a winch (137) and a winch
driven cable (138) connectable to the top drive unit and adapted to transfer, e.g.
slide, the top drive unit into the mast in its substantially horizontal assembly position.
3. Drilling rig system according to any of claims 1-2, wherein the frame comprises one
or more rails (137) that are aligned with said one or more rails of the mast when
the frame of the temporary removable installation device is positioned in line with
an end of a mast section of the mast in said substantially horizontal mast assembly
position, and wherein the top drive unit comprises one or more rail followers that
are engaged with the one or more rails of the frame prior to said transfer into the
mast and then are engaged with said one or more rails of the mast upon transfer into
the mast.
4. Drilling rig system according to any of claims 1 - 3, wherein the mast is adapted
to be - in its substantially horizontal assembly position - with its open front facing
down, e.g. said open front at a height of less than 1 metre above the ground.
5. Drilling rig system according to any of claims 1 - 4, wherein the mast sections comprise
left-hand and right-hand vertical front posts and rear corner posts, with each front
post being connected by bracings to a respective rear corner post to form the respective
side wall of the mast and said rear corner posts being connected to each other by
bracings to form the respective rear wall of the mast, and wherein, preferably, a
vertical rail is fixed to each of the front posts and the top drive unit is guided
along said vertical rails.
6. Drilling rig system according to any of claims 1 - 5, wherein the top mast section
comprises a crown block assembly with cable sheaves mounted to the top mast section
and a travelling block assembly with cable sheaves, wherein, preferably, one or more
cables are pre-reeved over said crown block and travelling block assembly.
7. Drilling rig system according to any of claims 1 - 6, further comprising at least
one drive assembly (45) to move the drilling rig mast with the top drive between the
substantially horizontal mast assembly position and the vertical operational position.
8. Drilling rig system according to any of claims 1 - 7, wherein an intermediate mast
section of the mast comprises a drag chain with one or more electrical and/or hydraulic
lines connectable to the top drive unit.
9. Method for bringing a modular transfigurable drilling rig system according to any
of claims 1 - 8 into operational mode, said method comprising:
- placing the base structure on the ground;
- positioning the lower mast section in a generally horizontal position thereof such
that the foot end of the lower mast section is brought adjacent the base structure;
- connecting the foot end of the lower mast section to the base structure;
- positioning one or more further drilling rig mast sections in substantially horizontal
position thereof in line with the lower mast section and interconnecting said mast
sections;
wherein the method further comprises:
- positioning the vehicle transportable top drive unit installation device in line
with the end of a mast section of the mast in said substantially horizontal mast assembly
position, e.g. of an intermediate mast section of the mast prior to assembly of the
top mast section;
- transferring, e.g. sliding, the top drive unit from the frame of the installation
device into the drilling rig mast in the substantially horizontal mast assembly position
thereof;
- removing the frame of the temporary removable vehicle transportable top drive unit
installation device (130), prior to moving the drilling rig mast with the top drive
unit towards its vertical operational position.
10. Method according to claim 9, for bringing a drilling rig system according to claim
2 into operational mode, further comprising the step of operating the translation
drive of the top drive unit translation assembly to transfer, e.g. slide, the top
drive unit from the frame of the installation device into the drilling rig mast in
the substantially horizontal mast assembly position thereof, wherein preferably the
translation drive comprises a winch and a winch driven cable connectable to the top
drive unit, and wherein the winch is operated to transfer, e.g. slide, the top drive
unit into the mast in its substantially horizontal assembly position.
11. Method according to any of claims 9-10, wherein the frame comprises one or more rails
that are aligned with said one or more rails of the mast when the frame of the installation
device is positioned in line with an end of a mast section of the mast in said substantially
horizontal mast assembly position, and wherein the top drive unit comprises one or
more rail followers that are engaged with the one or more rails of the frame prior
to said transfer into the mast and then are engaged with said one or more rails of
the mast upon transfer into the mast.
12. Method according to any of claims 9-11, wherein the mast is assembled - in its substantially
horizontal assembly position - with its open front facing down, e.g. said open front
at a height of less than 1 metre above the ground.
13. Method according to any of claims 9-12, wherein the top drive unit installation device
is offloaded from a road vehicle and positioned in line with and connected to the
respective mast section, and wherein the top drive unit is subsequently transferred
into the mast.
14. Method according to any of claims 9-13, wherein the vehicle transportable top drive
unit installation device is positioned in line with the end of an intermediate mast
section of the mast in said substantially horizontal mast assembly position, and wherein
the top drive unit is then transferred into said intermediate mast section, and wherein
the frame of the installation device is then removed, and wherein subsequently the
top mast section is positioned in line with the already assembled part of the mast
and connected thereto.
15. Method according to any of claims 9-14, wherein the top mast section comprises a crown
block assembly with cable sheaves mounted to the top mast section and a travelling
block assembly with cable sheaves, wherein, preferably, one or more cables are pre-reeved
over said crown block and travelling block assembly,
and wherein the method comprises the step of connecting the travelling block assembly
to the top drive unit that has been transferred into an adjoining intermediate mast
section, e.g. wherein the travelling block assembly comprises a hook that is engageable
with the top drive unit.