AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Innovation Patent Applicant(s): Foremost Industries Ltd. Invention Title: APPARATUS AND METHOD FOR DRILLING The following statement is a full description of this invention, including the best method for performing it known to us: -2 APPARATUS AND METHOD FOR DRILLING FIELD OF THE INVENTION 10011 This invention relates to a drilling rig transportable on trailers for set up in different locations for well drilling, and in particular to a drilling rig that can be 5 operated in both a coiled tubing injector mode for drilling with coiled tubing and a top drive mode for drilling with jointed pipes. BACKGROUND OF THE INVENTION 10021 Over the last couple of decades, the technique of drilling wells, particularly those relating to oil and gas production, by way of injection and withdrawal of a length 10 of continuous tubing, instead of the earlier process of drilling with jointed drill pipe, has been continuously developing. The two different techniques are in fact commonly used alternatively in the drilling of a single hole, and there exists hybrid drilling rigs equipped to alternatively handle both conventional jointed pipe and flexible coiled tubing. During the early development years of coiled tubing technology, it was common 15 for the injector component of the system and the tubing reel to be separately trucked to a well site, and at which time the injector component was mounted and attached to the well head and the tubing reel located nearby with the tubing to be fed into the mounted injector. During further development of this technology, systems were used wherein both the tubing reel and a boom structure for handling the injector were mounted on 20 separate trailers on which they remained during the well drilling process. Examples of such equipment are shown as prior art in U.S. Pat. No. 7,028,781 of Hill and U.S. Pat. No. 7,111,689 of Wise et al. However, for the sake of convenience and efficiency in set-up and operation more current designs of equipment are based on single load, one truck design, which has the advantage of the coil tubing remaining stabbed or installed 25 in the injector between rigging down the coiled tubing injector operation at one site and then rigging it up again at a new site, thus reducing the down time. However, such known designs have a significant disadvantage as related technology has developed to the stage that much deeper drilling is possible and indeed desirable in many situations, but the depth available with known rigs is limited by the length of coil available in the 2252921_1 (GHMutters) -3 reel. The reel size, on the other hand, is in turn determined as to what total size and weight of a trailer is possible for movement over roadways. At present such rigs include coiled tubing storage reels which are at a maximum capacity in this regard. SUMMARY OF THE INVENTION 5 [003] It is an object of the invention to provide a drilling rig which may be transported to a drilling site for drilling deeper wells than is presently possible and capable of being rigged up or rigged down in an acceptable period of time. 10041 It is also an object of the present invention to provide a drilling rig which may allow rapid alternation between top drive operating mode for drilling with jointed pipe 10 and coiled tubing injector mode for drilling with coiled tubing. [0051 It is further an object of the invention to provide a drilling rig wherein separate trailer components are provided to separately transport the tubing storage reel and the mast and injector components to a well site and wherein the components are combined to provide an operational site having the operating characteristics and advantages 15 similar to those of more recently developed single load type. [0061 According to one aspect of the present invention, there is provided a drilling rig including first and second transport trailer components, each having a load supporting deck providing a forward section including a connector means for independent attachment to fifth wheels of separate tractor units so as to provide separate loads from 20 one site to another. The first transport trailer component includes an intermediate section contiguous with the forward section and providing support means for a tubing storage reel, and a rearward section contiguous with the intermediate section thereof for joining with the forward section of the second transport trailer component. The second transport trailer component includes an intermediate section contiguous with the 25 forward section thereof and a rearward section contiguous with its intermediate section. The rearward section of the second transport component has mounted thereon a mast carrying a top drive, the mast having a pivotal connection with the rearward section of the second transport trailer component for movement of the mast between a vertical position and a substantially horizontal position overlying the intermediate and forward 2252921_1 (GHMaters) -4 sections of the second transport trailer component. The rearward section of the second transport component also has mounted thereon a deployment arm carrying a tubing injector, the deployment arm having a pivotal connection with the rearward section of the second transport trailer component for movement between a horizontal storage 5 position overlying the intermediate and forward sections of the second transport trailer component and a vertical operating position in which the deployment arm enables the coiled tubing injector to engage the mast. Accordingly, on aligning the forward section of the second transport trailer component to the rear section of the first trailer component at a drill site, a continuous coiled tubing injector rig is provided. 10 10071 More specifically, the forward section and the intermediate section of the first transport trailer component form a raised portion of the first transport trailer component in relation to a lowered portion thereof forming the rearward section of the first transport trailer component. The forward section of the second transport trailer component is formed by a raised portion thereof in relation to the intermediate and 15 rearward sections thereof. Thus, the forward section of the second transport trailer component overlies the rearward section of the first transport trailer component when the components are in an operating relationship. 10081 In a preferred embodiment of the coiled tubing injector system, there is provided a gripper box carried on the supporting deck of the first transport trailer component 20 rearwardly of the support means for the tubing storage reel and positioned to hold a free end of coiled tubing stored on the tubing storage reel. 10091 More specifically, the gripper box is attached to the first transport trailer component by a control arm for locating the gripper box above the load supporting deck of the first transport trailer component. This control arm may include a double acting 25 hydraulic cylinder controllable for locating the free end of the coiled tubing in a desired position relative to the load supporting deck and the coiled tubing injector. 100101 Yet another aspect of the invention resides in a method of feeding a coiled tubing into and out of a well at a well-head site, including the steps of moving separate first and second transport trailer components to the site. In this aspect of the invention, 30 the transport trailer components each have a rear portion and a forward portion for 22529211 (GHMatters) -5 overlying and attachment to a fifth wheel of a tractor unit. The first transport component further has an intermediate portion carrying a motor driven tubing storage reel for rotation about a transverse axis, and a gripping member rearwardly of the tubing storage reel for holding a free end of the tubing on the reel. The second transport 5 component has a mast carrying a top drive mounted on the rear end portion thereof and a deployment arm carrying a coiled tubing injector. The mast is pivotally connected to the second transport component and includes motor means for raising and lowering the mast between a lowered transport mode overlying the second transport component in the transport mode and an upright operational mode. In this method a process is 10 included which involves the positioning of the second transport component in a location with a rear portion over the well head site, and raising the mast to commence top drive operations. The first transport component is backed into alignment with the forward end portion of the positioned second transport component with the rear portion of the first transport component juxtaposed the forward portion of the second transport 15 component so as to form substantially continuous aligned upper decks of the first and second transport components. The gripping member on the first transport component is then released to allow the free end of the stored coiled tubing to pass from the storage reel and to be drawn over a goose-neck of the injector by initially energizing the injector. When coiled tubing operations are to be commenced, the deployment arm is 20 raised to a fully upright operating position placing the coiled tubing injector in alignment with the mast and allowing the injector to engage the mast. Drilling operations with coiled tubing are then commenced while continuing to feed the tubing from the reel and through the injector and into the well. [00111 More specifically the process may further include the steps of attaching to the 25 free end of the stored coiled tubing a rear end of a snake member, prior to releasing the gripping member. A forward end of the snake member is at least partially passed through the injector, and the injector further operated after the releasing of the gripping member to draw the snake member completely through the injector so that the free end of the stored coiled tubing is pulled over the gooseneck and enters the injector. The 30 snake member is then disconnected and removed from the free end of the coiled tubing. 2252921_1 (GHMatters) -6 100121 The process may further include the following steps after completion of the drilling operation: withdrawing the tubing from the drilled well by reverse operation of the injector and recoiling the tubing on the storage reel lowering the boom, clamping the free end of the coiled tubing by the gripping member, and removing the first 5 transport component from the site, and then separately moving the second transport component from the site. (00131 The process more specifically includes the steps of terminating operations of the injector and the recoiling by the storage reel when the free end of the tubing leaves the well and before entering the injector, and thereafter attaching to the free end of the 10 tubing a forward end of the snake member; reactivating the operation of the injector and the storage reel to continue rewinding the tubing until the free end of the tubing approaches the clamping member; reactivating the gripping member to hold the free end of the tubing; and disconnecting the snake member from the free end of the tubing prior to separately removing the first and second transport components from the site. 15 BRIEF DESCRIPTION OF DRAWINGS 100141 FIG. I is a side and rear elevational view of the drilling rig of the present invention in a coiled tubing injector drilling mode; [00151 FIG. 2 is a side and rear elevation view showing a first transport trailer component of the present invention on which the coiled tubing reel and the control arm 20 is mounted; 100161 FIG. 3 is a side and rear elevational view showing a second transport trailer component of the present invention on which the mast, top drive, deployment arm and injector head are carried; 100171 FIG. 4 is a side and rear elevational view showing the combined components of 25 FIGS. 2 and 3, located together to form the drilling rig of the present invention with the mast and top drive raised to a top drive drilling mode and the deployment arm and coiled tubing injector in an initial stabbing mode prior to being raised to the working mode shown in FIG. 1. 2252921_1 (GHMatters) -7 [00181 FIG. 5 is a side elevational view showing the combined components of FIGS. 2 and 3, located together to form the drilling rig of the present invention with the mast raised and in a top drive drilling mode and the lifter arm and coiled tubing injector in a partially raised position prior to being fully raised to the coiled tubing injector drilling 5 mode shown in FIG. 1. [00191 FIG. 6 is a side elevational view showing the combined components of FIGS. 2 and 3, located together to form the drilling rig of the present invention with the mast and top drive raised to a top drive drilling mode adjacent to a jointed tube carrier platform and the blow out preventer building. 10 [00201 FIG. 7 is a top view of the site layout during drilling operations showing the configuration of the platforms and carriers for the various systems. 100211 FIG.8a is a top a side elevational view respectively of the blow out preventer storage building laid on the ground and FIG. 8b is a side elevation view of the same mounted on a trailer ready for transport. 15 DETAILED DESCRIPTION OF THE INVENTION 100221 An assembled form of a drilling rig 10 of the present invention is shown in FIG. 1, The first transport trailer component 11 is shown in FIG. 2 in a transport mode, having a conventional connector means 13 for interconnection with a fifth wheel of a first transport tractor 15a. The second transport trailer component 12 is shown in FIG. 3 20 in a transport mode having a conventional connector means for interconnecting with a fifth wheel of another transport trailer 15b. [00231 The first transport trailer component 11 has a forward section 20 (FIG. 2), which is at a raised level relative to the rearward section 21. The forward section 20 of the first transport trailer component I1 may be provided with an outrigger 22 (shown in 25 retracted position) or the like for support when this component is standing alone. The connector means 13 is located within this forward section 20 which is located at a height under which the tractor fifth wheel 14 may be backed for connection for towing of the first transport trailer I I from one site to another. The rearward section 21 of the first transport trailer 11 is supported by a wheeled support undercarriage 23 and is at a 2252921.1 (GHMatters) -8 lower level than the forward section 20, so that the upper surface of the rearward section 21 is at a level to receive thereover a forward section 24 of the second transport trailer component (FIG. 1). The forward section 20 of the first transport trailer component is provided with outriggers 22 (shown in retracted position) for support 5 when separated from the transport tractor 15a. [00241 Located behind the forward portion 20 of the first transport trailer component 11, and at the same level, is an intermediate section which includes mounting means for tubing storage reel 26. The mounting means are secured on top of a pair of spaced side rails of the intermediate section in order that the tubing storage reel 26 occupies the 10 space between the rails and the lowermost circumference of the reel is well below the raised intermediate section 20 of the first transport trailer component 11. The reel 26 is journalled by way of its mounting means for rotation and such rotation is controlled by way of a drive means system 30 including a hydraulically driven motor 31. Prior to a stabbing procedure which will be described in more detail below, the coiled tubing 60 15 wound in the storage reel has a free end 32 which extends through a level wind device 33 carried by the framework of the intermediate section 27 of the first transport trailer component 11. The free end is further secured by a gripper box 34 affixed to the frame of the first transport trailer 11 by a control arm 35. The control arm 35 may be any articulating arm such as a knuckleboom crane and is connected at its lower end to the 20 rearward section of the first transport trailer component 11. The control arm 35 may be provided with a plurality of sections that may be extendable and pivotable with respect to each other so as to position the gripper box at a desired distance from the deck of the first transport trailer component, and aligned relative to a tubing injector 36 mounted on a deployment arm 70 carried on the second transport trailer component 12, when the 25 two components 11 and 12 are aligned. [00251 The second transport trailer component 12, as shown in FIG. 3, includes a continuous framework forming a forward section 24, and intermediate section 41, and a rearward section 42. The forward section 24 is raised relative to the other sections 41,42, and, as shown, has provided at a forward end thereof the fifth wheel connector 30 means to provide attachment of the second transport trailer component 12 to the transport tractor 15b for travel to and from each drill hole site independent of the first 22529211 (GHMater) -9 transport trailer component 11. The forward section 42 is provided with outriggers 43 for supporting the forward end of the second transport component 15b separate from the tractor, and to allow the rearward section of the first transport trailer component 11 to be backed into a position where the front of the forward section 24 overlies the 5 rearward section 21 as shown in FIGS. I and 4. There is supported on the forward section 24 of the second transport trailer component 12 an electric or diesel motor and pump unit, a hydraulic oil cooler and an hydraulic tank, shown generally as 40, the output of the pump being connected to the various controls relating to the hydraulically driven items on the two transport trailer components of the overall system when 10 connected. Also mounted on the forward section 24 and located above the just mentioned system 40 for supplying pressurized hydraulic fluid, is a stabbing platform (not shown) on which drilling personnel can stand while conducting the stabbing procedure described further below. 10026] Located below the rearward section 42 of the second transport trailer component 15 12 is a wheeled undercarriage 46 which carries a major portion of the weight at the rear end of the second transport trailer component 12. An auxiliary wheeled undercarriage (not shown) may also be attached to the wheeled undercarriage 46 at the rear of the main frame of the second transport trailer component 12. The auxiliary wheeled under carriage is removable and used during transport for load distribution to the surface over 20 which travel is being made. Located at the very rear end of the mainframe of the second transport trailer component is a mast base 50 to which the bottom end of the mast 37 is pivotally connected by a pin connector 52. A hydraulic cylinder is pivotally connected at one end to the frame of the trailer component 12 and at its other end to the mast 37, so that on expansion of the hydraulic cylinder, the mast 37 can be pivoted about the pin 25 connection 52 from a horizontal transport position as shown in FIG. 3, to an upright working mode as shown in FIG. 1 in which position it can be fixed by the insertion of a locking pin in aligned holes in the lower part of the mast 37 and the mast base 50. 100271 Also located on the rearward section 42 of the second transport trailer 12 is an injector deployment arm 70 to which the coiled tubing injector 36 and attached 30 gooseneck 61 are mounted. The injector may be detachably mounted to the deployment arm during transport and stabbing operations described below. The injector may also 22529211 (GHMatters) - 10 remain attached to the deployment arm during operations. The deployment arm 70 is pivotally attached at its base to the frame of the second transport trailer 12 so that it can be pivoted from its horizontal position during transport and stabbing operations to a substantially upright position for mounting the coiled tubing injector to the mast. A 5 hydraulic cylinder or other actuator means may be used to raise and lower the deployment arm. A vertical support member 72 is provided to support the deployment arm 70 and attached injector 36 and gooseneck 61 while the deployment arm is in the horizontal transport and stabbing positions. 100281 The top drive 54 is carried at a desired location on the mast above the deck of 10 the second transport trailer component. There may also be included at the base of the mast, a rotary table. During top drive operations, the top drive 54, is connected by a cable 56 via a crown 55 at the top of the mast to a drawworks winch 57 mounted on intermediate section 41 of the second transport trailer component 12. A work platform is also provided in the area of mast base 50. 15 100291 As will be described further below, when in coiled tubing operation mode, tubing 60 from the storage reel 26 passes over a gooseneck 61 before entering the tube injector 36. The gooseneck 61 is attached at its base to the injector 36 and has a hinged outer portion 62. The outer portion 62 is connected to the injector 36 per se by a hydraulic cylinder 63, which when contracted pulls the gooseneck to a contracted form 20 thereby allowing the deployment arm 70 to assume its horizontal transport mode of FIG. 3. 100301 In operation of the system of the present invention, normally the second transport trailer component 12 would be pulled by the transport tractor 15b to a site where the well is to be drilled, and this component would be placed with the mast base 25 50 substantially located over the well centre for drilling. The outriggers 43 are deployed and the mast 37 is raised to an upright top drive drilling position shown in FIG. 4, and when the first transport trailer component 11 is brought to the site by the transport tractor 15a, it may be backed into the position shown in FIG. 4 with the forward section 24 of the second transport trailer component overlying the lower rearward section 21 of 30 the first transport trailer component 11 so as to form a continuous upper deck of the thus formed rig. Outriggers 22 (shown in retracted position) at the front of component 22529211 (GHMaters) - I1 11 are then lowered to stabilize the front of the component 11, as the transport tractor 15a is removed, and the appropriate connections, including the hydraulic system which is common throughout the connected components 11 and 12, are performed. With the two components I1 and 12 appropriately aligned and positioned the components of the 5 control arm 35 can be positioned, tilted and extended, to bring the free end of the tubing 60 held by the gripper box 34 to a position in front of and aligned with the coiled tubing injector 36 so as to begin the stabbing process. Because the coiled tubing 60 on the reel 26, tends to unwind, the coil is maintained in tension as it is held by the gripper box 34. With the free end of the tubing held by the gripper box 34, it is connected end 10 to-end by an internal connector to a piece of tubing, herein termed a snake member or tubing snake, which is installed in place of the normal tubing into the tube injector 36. With the connection made, the gripper box is released as the injector is then used to prevent the tubing from unwinding off the storage reel. This is followed by the tube injector being energized so that tubing is run from the storage reel through the tube 15 injector 36, and as the connection between the free end of the tubing and the tubing snake has passed through the injector, the tubing snake is removed. During feeding of the tubing through the tube injector 36, the storage reel is driven by its drive system 30, acting much like a mooring winch. The drive motor 31 is activated to pull coil from the storage reel when the tubing is being pushed into the hole by the tubing injector and 20 pulling tubing from the tubing injector when the tube is being drawn out of the hole. 100311 The above operations of stabbing the tubing in the injector in preparation for coiled tubing operations may be carried out while the rig is operating in the top drive mode with jointed tubes 58, thereby minimizing the amount of time required for changing operating mode. When it is desired to switch to coiled tubing operations, the 25 top drive is moved to a position towards the top of the mast, the deployment arm 70 and attached injector 36 is raised from the horizontal storage and stabbing positions shown in FIG. 4 through an intermediate partially raised position shown in FIG. 5 to the fully upright position in the coiled tubing operation mode as shown in FIG. 1. 100321 The injector 36 is raised by the deployment arm 70 and mounted on the mast 37 30 for coiled tubing operations as shown in FIG. 1. Any appropriate means, such as hydraulic pins, may be used to engage the injector with the mast and guiding ramps 2252921_1 (GHMatters) - 12 may be provided to ensure alignment of the injector with the mast. During injector operations, the injector may remain attached to the deployment arm, however, the weight of the injector is primarily transferred to and supported by the mast. 100331 The deployment arm 70 may be provided with telescoping functionality in order 5 to more easily engage the injector 36 with the mast 37 and additionally, to mount the injector 36 at various positions on the mast 37. In an alternate embodiment (not shown), the injector 36 may be mounted to the top drive 54 instead of directly to the mast 37. The weight of the injector, in this embodiment, would be ultimately transferred to the mast via the top drive. 10 [00341 The location of the deployment arm 70 with attached injector 36 on the same trailer as the mast 37 and adjacent to the mast 37 allows for easier and more efficient alignment when engaging the injector with the mast compared to other conventional trailer configurations where the injector, already stabbed with the coiled tubing reel, is transported on the same trailer as the coiled tubing injector reel. 15 100351 If the operations have to be switched back to top drive mode for drilling with jointed tubes 58 as shown in FIG. 6, the injector will be disengaged from the mast and the deployment arm lowered to the horizontal storage position shown in FIG. 4 and FIG. 6 while top drive operations are commenced. Thus, operations can be rapidly and efficiently alternated between coiled tubing and top drive modes using the procedures 20 described above. 100361 When the working operations with the coiled tubing is finalized, the deployment arm 70 is returned to the position shown in FIG. 4 and the tubing snake 54 is again attached to the end of the free end of the tubing 60 as it is pulled from the hole, the injector 36 then being operated to pass the snake until the free end 32 of the tubing 25 approaches the area of the stabbing platform, and at which time the free end 32 of the tubing 60 is again clamped by the gripper box 34 and disconnected from the tubing snake 65, which may remain in the tube injector 36. At this time the first transport trailer component 11 may be disconnected in relation to the second transport trailer component 12 and pulled away from the second transport trailer component by 2252921_1 (GHMatters) - 13 transport tractor 15a and at which time the mast 37 may be further lowered to its transport mode on the second transport trailer component 12, as shown in FIG. 3. 100371 FIG. 7 shows the site layout during operations, in particular, the location of the blow out preventor (BOP) building 710 storing the BOP 712 apparatus adjacent the 5 mast on the second trailer component 12 such that the BOP can be easily slid in and out of position in alignment with the mast. FIG. 7 also shows the combination building 740, the structure housing the mud tank and the mud pump system 730, the jointed tube carrier platform 720 for storing the jointed tubes 58. FIG. 8 shows a top and side view of the doghouse/BOP building 710 laid on the ground during operations. FIG. 8 also 10 shows the doghouse/BOP building 710 mounted to a trailer and being wheeled to and from a site before and after operations. 100381 It may be understood from the above that by utilizing the separate transport trailer components I I and 12 as described above the coiled tubing injector system of the present system may be transported to the site with coiled tubing of a quantity which 15 allows for much deeper drilling while exposing the roadways to acceptable load requirements. The storage reel can be made wider to carry more coiled tubing as there are less dimensional restrictions than with the single trailer designs now in use. Moreover, while the present invention requires stabbing and unstabbing the tubing when reaching and leaving a site, respectively, it is apparent from the above that the 20 present invention also provides for procedures which significantly reduce the time lost during the stabbing operations by performing them while the rig is operating in top drive mode with jointed tubes. Because of the manner in which the two transport trailer components 11, 12 are arranged to form a continuous working coiled tubing injector system and in view of the provisions and location of elements, including the 25 deployment arm adjacent the mast on the same trailer, it can be appreciated that the set up at a well site, stabbing of the well and the removal of the coiled tubing and complete withdrawal from the site can be carried out in a manner involving no significant procedural steps different with the now popular single component rigs. On the other hand the operation with the present invention effectively has the ability of drilling 30 deeper wells as compared to such single component rigs. 22529211 (GHMatters) - 14 While a single embodiment of the invention has been described variations within the spirit of the present invention as defined in the accompanying claims will be obvious to those skilled in the art. 2252921i1 (GHMatlers)