WO2009101377A1

WO2009101377A1 - Method and apparatus for facilitating erection of a drilling rig

Info

Publication number: WO2009101377A1
Application number: PCT/GB2008/050927
Authority: WO
Inventors: Nicolas Youssef Hanna; Elie Jean Chehade
Original assignee: National Oilwell Varco, L.P.; Lucas, Brian Ronald
Priority date: 2008-02-13
Filing date: 2008-10-09
Publication date: 2009-08-20
Also published as: CA2711458A1; RU2010137847A; US20090200856A1

Abstract

A method and apparatus for facilitating erection of a drilling rig com prising a substructure (18), a mast (20) movably connected to the substructure (18), a drawworks apparatus (30) with cables (31, 32, 33) for raising and lowering the mast (20), a drawworks control system (CS) for controlling the drawworks apparatus (20) as the mast (20) is raised or lowered, characterised in that the method comprises the step of controlling the raising and lowering of the mast (20) with a remote control system (A), such that an operator can walk around with the remote control system (A).

Description

METHOD AND APPARATUS FOR FACILITATING ERECTION OF A

DRILLING RIG

This invention relates to a method and apparatus for facilitating erection of a drilling rig and particularly, but not exclusively, to a method and apparatus for facilitating erection of a mast of a mobile land rig.

The prior art discloses a variety of drilling rigs used for various wellbore operations ; for example , and not by way of limitation, U.S. Patents 3,340,938; 3,807,109; 3,922,825; 3,942,593; 4,269,395; 4,290,495;

4,368,602; 4,489,526; 4,569,168; 4,837,992; 6,634,436;

6,523,319 and the references cited in these patents - all these patents incorporated fully herein for all purposes .

In many land drilling operations , land rigs are delivered to a site, assembled and then disassembled.

One of the first steps in assembling land rigs is to raise a rig mast from a substantially horizontal transported position to a substantially vertical operational position. In many prior methods, the mast is raised and lowered by personnel on structure immediately adjacent the mast with controls and related devices that are hard-wired to mast raising apparatuses such as a drawworks .

U.S. Patent 3,922,825 discloses a rig with a stationary substructure base and a movable substructure base mounted thereon which is coupled to the stationary base and swings upright into an elevated position on a series of struts that are connected to the stationary base with swivel connections at each end. The movable base is otherwise stationary since neither the stationary base nor the movable base are mobile or repositionable without the use of an auxiliary crane or the like. The movable substructure base and the drill mast are raised with a winch mounted on an auxiliary winch truck.

U.S. Patent 3,942,593 discloses a mobile well drilling rig apparatus which has a trailerable telescoping mast and a separate sectionable substructure assembly with a rig base, a working floor, and a rail structure. The mast is conveyed to the top of the substructure by rollers and is raised by hydraulic raising apparatus to an upright position. With such a system the the mast assembly can be relatively long when transporting it and the mast can be unstable during raising. This system uses drawlines and winch apparatus to raise the mast onto the working floor.

U.S. Patent 6,634,436 discloses a mobile land drilling apparatus and method. The rig has a mobile telescoping substructure box. A lifting apparatus selectively supports the mobile telescoping substructure box unit in a raised position and lowered position. An extension cylinder further extends the mobile telescoping substructure box unit in telescopic extension. A stationary frame member and a telescoping frame member have a plurality of cables attached thereto for supporting the telescoping frame member when extended. A trolley winch allows completion of the rig assembly without an external crane. The inventors have noted that controlling the raising and lowering of the mast in the erection of a drilling rig is not an easy task and that errors can be made which could cause damage to the equipment and to personnel. It should be noted that the drawworks is very powerful and can quite easily cause damage to equipment if used incorrectly.

In accordance with the present invention, there is provided a method for facilitating erection of a drilling rig comprising a substructure, a mast movably connected to the substructure, a drawworks apparatus with cables for raising and lowering the mast, a drawworks control system for controlling the drawworks apparatus as the mast is raised or lowered, characterised in that the method comprises the step of controlling the raising and lowering of the mast with a remote control system, such that an operator can walk around with the remote control system. This allows the operator to move to the bet vantage point for the particular stage in operation fo erecting a rig.

Preferably, the substructure comprises a floor and at least one leg, the floor erectable on the at least one leg, the method further comprising the step of controlling the erection of the floor on the at least one leg.

Advantageously, the drawworks apparatus comprises a brake apparatus, the method further comprising the step of activating the brake apparatus remotely using the remote control system. Preferably, the brake apparatus comprises a park brake, an eddy current brake, and service brakes, the method further comprising the steps of activating at least one of the emergency park brake, an eddy current brake, and service brakes. Preferably, the park brake is an emergency park brake. Advantageously, the remote control system comprises a joystick apparatus for controlling the service brakes to control speed of movement of the mast during lowering and raising. Preferably, the remote control system includes a deadman switch on the joystick apparatus, the method further comprising the step of applying the service brakes if the deadman switch is not held or depressed. Advantageously, the brake apparatus comprises a cooling system, the method comprising the step of activating the cooling system remotely using the remote control system. Preferably, the park brake comprises an air system for providing air to the park brake, and pressure indicating apparatus in communication with the remote control system, the method comprising the step of indicating the system air pressure on the remote control system.

Preferably, the remote control apparatus comprises a switch, the method further comprising the step of activating the switch to turn the drawworks apparatus on or off. Advantageously, the drawworks apparatus includes a transmission and a motor, the method further comprising the step of activating the transmission (37) with the remote control system. Preferably, the motor is controllable by the remote control system.

Advantageously, the drawworks apparatus is operable in a forward mode and in a reverse mode , the method further comprising the step of controlling the drawworks apparatus into a forward or reverse mode using the remote control system.

Preferably, the method further comprises the step of displaying real time information on the remote control system. Preferably, the real time information includes: hook load; pressure readings on brakes; pressure of driller side brakes; and rig hydraulic pressure; as well as other rig operational parameters .

Preferably, the drilling rig comprises a fixed rig control system, which may be fixed to the lorry or other conveying vehicle, with an enable switch for selectively enabling the remote control system, the method further comprising the step of using the enable switch to allow or disallow the remote control system for operation.

Preferably, the remote control system comprises hookload indicating apparatus .

The present invention also provides an apparatus for facilitating erection of a drilling rig comprising a substructure, a mast movably connected to the substructure, a drawworks apparatus with cables for raising and lowering the mast, a drawworks control system for controlling the drawworks as the mast is raised or lowered, and a remote control system for remotely controlling the drawworks control system to raise and lower the mast. Preferably, the person using the remote control system is spaced apart from the drilling rig using the remote control system. Advantageously, the remote control system is hand held. Preferably, the remote control system is in a single enclosure and may have a strap suitable for supporting the unit around the neck of an operator.

The present invention, in certain aspects, provides a system for remotely raising and lowering a mast of a drilling rig. In one particular aspect, an operator at a distance from a rig, using a remote control system in accordance with the present invention, controls a rig's control system, thereby remotely controlling a rig drawworks and associated cables that are used to raise and lower the mast of the rig. In one aspect, the rig has a substructure and the substructure is raised and lowered by remote control .

In certain aspects , the present invention discloses a system that includes a land rig with an erectable mast; a drawworks; a substructure; a rig control system for controlling the drawworks; and a remote control system in communication with the rig control system for controlling the drawworks to raise and lower the mast and for raising and lowering the substructure. This invention's teachings are applicable to any rig which has an erectable mast raised and lowered by a drawworks and substructure raised with hydraulic winches or cylinders. The method comprises the step of controlling the drawworks brakes remotely and using a joystick apparatus on a remote control system to remotely control the speed of raising or lowering a mast.

For a better understanding of the present invention, reference will now be made, by way of example, to the accompanying drawings , in which :

Figure 1 is a side schematic view of an apparatus in accordance with the present invention in a first step in a method of facilitating erection of a mast of a land rig in accordance with the present invention;

Figure 2 is an enlarged view of part of the apparatus shown in Figure 1 ; Figure 3 is a side view of the apparatus shown in

Figure 1, showing a second step in a method of facilitating erection of a mast of a land rig in accordance with the present invention;

Figure 4 is a side view of the apparatus shown in Figure 1, showing a third step in a method of facilitating erection of a mast of a land rig in accordance with the present invention;

Figure 5 is a side view of the apparatus shown in

Figure 1, showing a fourth step in a method of facilitating erection of a mast of a land rig in accordance with the present invention;

Figure 6 is a side view of the apparatus shown in

Figure 1, showing a fifth step in a method of facilitating erection of a mast of a land rig in accordance with the present invention;

Figure 7 is a side view of the apparatus shown in

Figure 1, showing a sixth step in a method of facilitating erection of a mast of a land rig in accordance with the present invention; Figure 8 is a side view of the apparatus shown in

Figure 1, showing a seventh step in a method of facilitating erection of a mast of a land rig in accordance with the present invention; Figure 9 is a top view of a console for a remote control device of the apparatus in accordance with the present invention; and

Figure 10 is a schematic view of an apparatus in accordance with the present invention.

Figure 1 shows an apparatus 10 in accordance with the present invention which comprises a drilling rig 12 with an A-frame 14 on a floor 16 mounted to a substructure 18. A mast 20 is pivotally connected to the floor 16 and initially in a substantially horizontal position to facilitate transportation of the apparatus 10 to site. The mast 20 has top sheaves 22 or crown, a set of raising sheaves 24, and a raising connection lug 26. A drill line 33 runs from a drawworks 30 over top sheave 22 to a travelling block 90. The drawworks 30 is used to winch line 33 in and out to raise and lower travelling block 90. The Line 33 runs around the sheaves 27 and raising sheaves 24, used to raise the mast 20 are attached together and lifted by the travelling block 90 when the travelling block 90 is pulled with the line 33 winched by the drawworks 30. Operations personnel use a cabin 28 on the floor 16. A rig control system 34 controls the drawworks 30.

The drill line 33 extends over a "brakeover" sheave 35 down to the drawworks 30. The cables 31 and 32 extend over the raising sheaves 24 (for example eight in total) fixed in different areas on the mast and A-frame and are attached to a slingline equalizer 91 by the traveling block 90. An operator A with a remote control system 40 in accordance with the present invention is spaced-apart from the drilling rig 12. The remote control system 40 remotely controls the rig control system 34. As shown in Figure 3, the operator A has activated the remote control system 40 to take control of the drawworks 30 via the rig control system 34; and has initiated raising of the mast 20. The mast 20 has pivoted upwardly from its initial horizontal position. Figure 4 shows the mast 20 pivoted further upwardly. The mast raising mechanism has been activated by the drawworks 30 spooling the drill line 33, while the traveling block 90 and the slingline equalizer 91 travel in the mast from bottom to top, and in turn the slingline equalizer 91 pulls with it the raising lines 31 and 32, in one aspect lift the mast.

As shown in Figure 5, the mast 20 is fully erect. As shown in Figure 6, raising of the substructure 18 has commenced (also done by remote control) to raise the floor 16 and derrick to a desired height above ground G, with the remote control system 40 remotely controlling raising/lowering apparatuses 18a, by controlling the flow of hydraulic fluid to the winches pulling them up. A cable tray or "grasshopper" support 81b is used with the system. Figure 7 illustrates further raising of the floor 16. Figure 8 shows the floor 16 raised to a desired height.

Figure 9 shows one embodiment of a remote control system 50 in accordance with the present invention useful as the remote control system 40 of Figure 1. Figure 10 is a schematic view showing connections between a drawworks DK (like the drawworks 30, Figure 1), with a motor or motors M and a brake system BS, a drawworks control system CS (like the system 34, Figure 1) and the remote control system 50. The drawworks has an emergency park brake, an eddy current brake, or "Baylor" brake, and typical service brakes . The brakes require cooling and the cooling system CT for the brakes is also controllable by the system CS.

The drawworks control system 50 has a housing 51 with a cable connector 52 for optional wired use of the system 50 and an emergency pushbutton 53 to push to stop the drawworks in an emergency. The connector 52 may also be used to connect a cable for programming devices of the system 50; to change system batteries; or to program system displays. An ON/OFF switch 54 controls power to the system 50. Power is provided by a battery BT mounted inside the remote control housing 51. A pushbutton 55 starts the drives 36 that provide power to the drawworks. A light 56 indicates whether the system 50 is ON (light lit) or OFF (light off) .

Mast raising is conducted with a transmission 37 of the drawworks , an internal component of the drawworks , in low gear and with a system Baylor brake 38 off. The switch 57 is switched to control the rig control system to switch the transmission 37 into low gear and the switch 58 is switched to switch the clutch 37a of the transmission 37 to a low clutch setting. A switch 59 controls the system CS to set and release the Baylor brake .

Switches 61, 62 control the system CS to turn ON pumps of the cooling system CT that supply cooling water to the brakes. Lights 61a, 62a indicate if the pumps are ON. A light 64 indicates when ON that the drawworks is ready to move the mast, for example, that the radio connection is set with good coverage, the drawworks is powered, and the remote control system 50 is in full control of the components . A switch 63 controls the system to place the drawworks in Forward (raise mast) or Reverse mode (lower mast) . Lights 63a (Forward mode) and 63b (Reverse mode) indicate the mode of the drawworks. A throttle knob 65 controls the system CS to control the DC current to the drawworks motor M.

Lights 66 indicate battery status of a battery BT. A light 67 indicates if ON that the emergency brakes have been applied. A light 68 indicates whether air being supplied to the drawworks to operate the clutch and transmission is at a sufficient level (for example appears green) . If this light appears red, this is an indication that the air pressure is too low. The display 71 displays the rig's hook load (for example in thousands of pounds). The displays 72, 73 display the pressure of the drawworks brake system BS (in psi) . Displays indicate pressure on the service brakes. The display 72 displays the pressure of the system's "off driller side" disc brakes and the display 73 displays the pressure of the "driller side" brakes.

The display 74 displays the pressure in psi of hydraulic fluid from a rig hydraulic pressure unit HPU. This fluid powers the hydraulic drawworks brake system BS (but not the eddy current brakes) . If this pressure goes below a pre-set level (for example 207 bars (3000 psi) ) the park/emergency brakes are automatically applied.

Pushing a parking brake button 75 applies the hydraulic brakes of the brake system BS, stopping the drawworks, and bringing to a stop raising or lowering of the mast. A light 75a indicates whether the drawworks has been stopped by pushing the button 75.

A joystick 80 controls the service brakes and thus controls the speed of raising (and of lowering) the mast. In one aspect pushing forward on the joystick 80 (toward the top of Figure 9) releases the service brakes, increasing the speed of raising (or of lowering) (arrow indicates "SERVICE BRAKE RELEASE" direction) ; or pulling back on the joystick decreases the speed. The joystick 80 has a deadman switch 81 which is pressed in order to release the brakes. If this deadman switch is not being pressed, the service brakes will be fully applied. Appropriate switches, for example switches SA, SB, and appropriate display (s) , for example display SC, are used in raising and lowering of a substructure (with corresponding devices and circuitry in the remote control system, as is true for all the functions of the remote control system) .

In a typical operational sequence using the system 50, the switch 54 is turned ON. Optionally, an enable switch ES of the system CS (for example on a driller's console DC) is activated so that the system 50 can take over.

Low/high gear, low/high clutch engagement, and the drawworks throttle controls at the system CS are disabled via relays in the control system and the driller's joystick throttle control is also disabled. Once the system CS recognizes that the remote control system 50 is enabled, it will disregard the driller's joystick throttle control and signals related thereto and follow the input from the joystick 80 of the system 50 and the remote control system 50 will have control of the drawworks speed. The control system CS receives a signal from the joystick 80 (from a radio receiver RR of the system 50) .

A splitter barrier SB (installed in the rig control system 34) splits a hookload signal from a transducer TD of the system CS, providing a hookload indicating signal to the system CS and to the system 50. Two transducers TS, TE of the HPU unit provide feedback to the driller's console DC. A splitter ST on each transducer provides signals to the system 50 indicative of the pressure on the brake system BS.

The driller can manually start the brake cooling pumps before commencing operations , or these pumps can be activated using the system 50.

A pressure switch PS for a rig air pressure measured next to the drawworks provides a digital signal to the system CS and to the system 50 and to the driller's console DC indicating the level of the system air pressure. A pressure switch PR indicates the pressure applied to the park brake and provides a signal indicative of whether the park brake is set or released.

An encoder EC of the system CS indicates whether the drawworks is in Forward or Reverse mode, and at what speed. Feedback for the Baylor brake condition is provided by the system CS. Pressure switches PU, PE on the low gear and clutch air supply indicate whether the gear and clutch are engaged.

In one particular mast raising operation in accordance with the present invention, SCR circuit breakers CB are closed and the drawworks control system is set to automatic. The rig floor is cleared of all personnel. The operator of the system 50 starts the brake water cooling pumps. The operator of the system 50 engages the low gear and insures the low gear is engaged; he sets the drawworks to Forward; and checks that the READY light is ON. He then turns the knob 65 so that the drawworks motor begins running. He then verifies that the HPU pressure (display 74) is around 138 bars (2000 psi) and verifies that the brake pressure (displays 73, 74) is around 83 bars (1200 psi) . He checks that the rig air pressure light 68 is ON and verifies that the auxiliary brake controller is powered. The Baylor brake is tested by setting it off and on again from the remote control system 50; and its feedback is checked. The raising of the mast is commenced by engaging the clutch, beginning to release the service brakes of the brake system BS, and moving the joystick 80 forward.

The operator should see the pressure dropping on both displays 72, 73 and the light 63a should illuminate. In emergency engagement of the park brake, the system cuts the pressure from the brake callipers and built in springs activate the brake.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a system for remotely controlling the raising and lowering of a drilling rig's mast, the system in certain aspects including a system for drilling operations, the system including: a drilling rig with a base; a mast movably connected to the base of the drilling rig; a drawworks system with cables for raising and lowering the mast, the cables connected to the mast; a drawworks control system for controlling the drawworks as the mast is raised or lowered; and a remote control system for remotely controlling the drawworks control system, the mast raisable and lowerable by a person spaced apart from the drilling rig using the remote control system. Such a system may include one or some, in any possible combination, of the following: the rig including a substructure, a floor on the substructure, apparatus for raising and lowering the substructure, and the remote control system for remotely controlling the apparatus for raising and lowering the substructure; wherein the mast is pivotably connected to the base and is pivotable on the base to achieve a raised position; wherein the drawworks system includes a brake system, the brake system remotely controllable using the remote control system; wherein the brake system includes an emergency park brake, an eddy current brake, and service brakes; wherein the brake system includes a cooling system, the cooling system remotely controllable by the remote control system; wherein the remote control system is battery powered by a battery; wherein the remote control system has ON/OFF apparatus for turning the drawworks on and off; wherein the drawworks system includes a transmission and a motor and the transmission is remotely controllable by the remote control system; wherein the drawworks is operable in a forward mode and in a reverse mode and the remote control system controls mode selection; wherein the motor is controllable by the remote control system; wherein the drawworks system includes a motor, a brake system, and a transmission, the brake system including service brakes, and the remote control system includes joystick apparatus for controlling the service brakes to control speed of movement of the mast during lowering and raising; wherein the remote control system includes a deadman switch on the joystick apparatus; display apparatus on the remote control system for displaying rig operational parameters; wherein the drilling rig includes a rig system with an enable switch for selectively enabling the remote control system; wherein the drilling rig includes hookload indicating apparatus in communication with the remote control system; and/or wherein the drilling rig includes a brake system with a park brake and an air system for providing air to the park brake, and pressure indicating apparatus in communication with the remote control system for indicating the system air pressure.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for remotely controlling a mast raising or lowering operation, the mast movably connected to a base of a drilling rig, the drilling rig including a drawworks system with cables for raising and lowering the mast, the cables connected to the mast, a drawworks control system for controlling the drawworks as the mast is raised or lowered, the method including: remotely controlling the drawworks control system with a remote control system, the mast raisable and lowerable by a person spaced apart from the drilling rig using the remote control system; and, in one aspect, such a method wherein the remote control system is battery powered by a battery; and/or wherein the drawworks system includes a brake system, the brake system remotely controllable using the remote control system, the brake system including an emergency park brake, an eddy current brake, and service brakes, the remote control system including joystick apparatus for controlling the service brakes to control speed of movement of the mast during lowering and raising, the method further including using the joystick apparatus to control the service brakes to control speed of movement of the mast during lowering and raising.

Claims

CLAIMS :

1. A method for facilitating erection of a drilling rig comprising a substructure (18) , a mast (20) movably connected to the substructure (18) , a drawworks apparatus (30) with cables (31,32,33) for raising and lowering the mast (20) , a drawworks control system (CS) for controlling the drawworks apparatus (20) as the mast (20) is raised or lowered, characterised in that the method comprises the step of controlling the raising and lowering of the mast (20) with a remote control system (A) , such that an operator can walk around with the remote control system (A) .

2. A method in accordance with Claim 1 , wherein the substructure comprises a floor (16) and at least one leg (18a, 18b), the floor (16) erectable on said at least one leg (18a, 18b) , the method further comprising the step of controlling the erection of said floor (16) on said at least one leg (18a, 18b) .

3. A method in accordance with Claim 1 or 2 , wherein the drawworks apparatus (30) comprises a brake apparatus

(BS, 38), the method further comprising the step of activating said brake apparatus remotely using the remote control system (A) .

4. A method in accordance with Claim 3, wherein the brake apparatus comprises a park brake, an eddy current brake, and service brakes, the method further comprising the steps of activating at least one of the emergency park brake , an eddy current brake , and service brakes .

5. A method in accordance with Claim 4, wherein the remote control system (A) comprises a joystick apparatus

(80) for controlling the service brakes to control speed of movement of the mast (20) during lowering and raising.

6. A method in accordance with Claim 5, wherein the remote control system (A) includes a deadman switch (81) on the joystick apparatus (80) , the method further comprising the step of applying the service brakes if the deadman switch is not held or depressed.

7. A method in accordance with any of Claims 3 to 6, wherein the brake apparatus (BS, 38) comprises a cooling system (CT) , the method comprising the step of activating the cooling system (CT) remotely using the remote control system (A) .

8. A method in accordance with any of Claims 3 to 7 , wherein said park brake comprises an air system for providing air to the park brake, and pressure indicating apparatus in communication with the remote control system, the method comprising the step of indicating the system air pressure on the remote control system (A) .

9. A method in accordance with any preceding claim, the remote control apparatus (A) comprises a switch (54) , the method further comprising the step of activating said switch to turn said drawworks apparatus (30) on or off.

10. A method in accordance with any preceding claim, wherein the drawworks apparatus (30) includes a transmission (37) and a motor (M) , the method further comprising the step of activating the transmission (37) with the remote control system (A) .

11. A method in accordance with any preceding claim, wherein the drawworks apparatus (30) is operable in a forward mode and in a reverse mode , the method further comprising the step of controlling the drawworks apparatus into a forward or reverse mode using the remote control system (A) .

12. A method in accordance with any preceding claim, further comprising the step of displaying real time information on said remote control system (A) .

13. A method in accordance with any preceding claim, wherein the drilling rig (10) comprises a fixed rig control system (34) with an enable switch for selectively enabling the remote control system (A) , the method further comprising the step of using said enable switch to allow or disallow the remote control system for operation .

14. A method in accordance with any of any preceding claim, wherein the remote control system (A) comprises hookload indicating apparatus (71) .

15. An apparatus for facilitating erection of a drilling rig comprising a substructure (18 ) , a mast (20) movably connected to said substructure (18) , a drawworks apparatus (30) with cables (31,32,33) for raising and lowering the mast (20) , a drawworks control system (CS) for controlling the drawworks (20) as the mast (20) is raised or lowered, and a remote control system (A) for remotely controlling the drawworks control system to raise and lower the mast (20) .

16. An apparatus as claimed in Claim 15, wherein said mast (20) is pivotably connected to said substructure

(18) and is pivotable on the substructure (18) to achieve a raised position.

17. An apparatus as claimed in Claim 15 or 16, further comprising a battery for powering said remote control apparatus .