阅读说明：本技术 侧部鞍形弹弓式连续运动钻机 (Side saddle-shaped catapult type continuous motion drilling machine ) 是由 阿希什·古普塔 帕迪拉·雷迪 当韦尔·利 于 2019-07-19 设计创作，主要内容包括：本公开涉及一种钻机,所述钻机包括钻机钻台、第一支撑结构和第二支撑结构、井架、下部钻探机、连续钻探单元、上部钻探机和上部井架组件。所述钻机钻台包括V型门,所述V型门限定V型门轴线,所述V型门轴线从所述钻机钻台的包括所述V型门的侧面垂直延伸。所述第一支撑结构和所述第二支撑结构限定具有横向廊道轴线的横向廊道,其中所述横向廊道轴线垂直于所述V型门轴线。所述钻机可用于对井眼的连续钻探。(The present disclosure relates to drilling rigs including a rig floor, and second support structures, a derrick, a lower drill, a continuous drilling unit, an upper drill and an upper derrick assembly the rig floor includes a V-shaped , the V-shaped defines a V-shaped axis, the V-shaped axis extends vertically from a side of the rig floor including the V-shaped , the and second support structures define a lateral corridor having a lateral corridor axis, wherein the lateral corridor axis is perpendicular to the V-shaped axis.)

1, A drilling rig, comprising:

a drill floor having a V-shape , a side of the drill floor including the V-shape defining a V-shape side of the drill floor, the V-shape having a V-shape axis defined perpendicular to the V-shape side of the drill floor;

a support structure and a second support structure, the rig floor being supported by the a support structure and the second support structure, the rig floor, the a support structure and the second support structure forming a beam structure, an open space between the a support structure and the second support structure and below the rig floor defining a transverse gallery having a transverse gallery axis, wherein the transverse gallery axis is perpendicular to the V axis;

a mast mechanically coupled to or more of said drilling rig floor, said support structure or said second support structure at or more mast mounting points, said mast comprising a frame having an open side defining a mast V-shaped side, said mast V-shaped side aligned with said V-shaped , said mast comprising or more racks coupled to said frame at said V-shaped side;

a lower drilling rig (LDM) coupled to the mast and vertically movable relative to the mast;

a Continuous Drilling Unit (CDU) mechanically coupled to the LDM;

an Upper Drilling Machine (UDM) coupled to the mast and vertically movable relative to the mast; and

an Upper Mud Assembly (UMA) coupled to the derrick and vertically movable relative to the derrick, the UMA including a drilling mud supply pipe adapted to supply drilling fluid to a tubular member defining an upper flow path gripped by the UDM.

2. The drilling rig of claim 1, further comprising a third support structure, the th, second, and third support structures defining a second transverse gallery axis.

3. The drilling rig of claim 1, wherein each of the th or second support structures comprises:

the lower box body is in contact with the ground; and

a support beam pivotably coupled to the lower box at a lower pivot point and pivotably coupled to the drill floor at an upper pivot point, the support beam forming a linkage between the lower box and the drill floor to allow the drill floor to move between a lowered position and a raised position as the support beam pivots relative to the lower box and the drill floor.

4. The drilling rig of claim 3, wherein at least of the th or second support structures further steps include a diagonal support beam extending between the lower box and the rig floor.

5. The drilling rig of claim 3, wherein further comprises or more hydraulic cylinders adapted to move the rig floor between the lowered position and the raised position.

6. The drilling rig of claim 1, further comprising a racking coupled to the derrick, the racking including or more fingerboards positioned to define slots in the racking in which tubular members may be positioned for storage in a vertical position on the drilling rig.

7. The drill rig of claim 6 wherein the fingerboard is arranged such that the slot extends radially from an open middle of the racking, such that a tubular member may be positioned radially into the racking relative to a location intermediate the racking.

8. The drilling rig of claim 6, further comprising a drill rod handler assembly.

9. The drilling rig of claim 8, wherein the drill rod handler assembly comprises:

a secondary derrick mechanically coupled to the rig floor;

a drill rod handler comprising a drill rod holder mechanically coupled to the secondary derrick by a drill rod handler arm and a drill rod handler carriage, the drill rod handler arm being mechanically coupled to the drill rod handler carriage.

10. The drilling rig of claim 1 wherein the mast is pivotably coupled to the mast mounting point by a pinned connection.

11. The drilling rig of claim 10 wherein the mast is movable between a vertical position and a horizontal position.

12. The drilling rig of claim 1 wherein said mast is comprised of two or more mast subcomponents that can be disengaged from one another when said mast is in a horizontal position.

13. The drilling rig of claim 1 wherein the support structure comprises or more travel actuators adapted to move the drilling rig along the transverse corridor axis through a wellsite.

14. The drilling rig of claim 13, wherein the travel actuator is rotatable such that the travel actuator is adapted to move the drilling rig in a plurality of directions through the wellsite.

15. The drilling rig of claim 1, further comprising or more of a mud tank, a make-up tank, a treatment tank, a mud treatment device, a compressor, a variable frequency drive, a drill wire winder, a driller's house, a throttle house, a mud gas separator skid, a stair tower skid, a hydraulic power unit skid, or an accumulator skid mechanically coupled to the drilling rig floor or the th or second support structure.

16. The drilling rig according to claim 15, wherein a driller's cabin or throttle chamber is positioned on or cantilevered from the rig floor.

17. The drilling rig of claim 15 wherein a mud gas separator skid and a stair tower skid are mechanically coupled to the drilling rig floor.

18. The drilling rig of claim 15 wherein a hydraulic power unit skid or an accumulator skid is mechanically coupled to or cantilevered from the support structure or the second support structure.

19. The drilling rig of claim 1, wherein the UDM comprises:

a UDM clamp adapted to engage a tubular member to allow the UDM to rotate the tubular member; and

a UDM slip positioned to engage the tubular member to allow the UDM to move the tubular member vertically.

20. The drilling rig of claim 19 wherein the tubular member engaged by the UDM clamp and the UDM slip is aligned with the rack of the derrick.

21. The drilling rig of claim 1, wherein the LDM comprises:

an LDM clamp adapted to engage a tubular member to allow the LDM to rotate the tubular member; and

an LDM slip positioned to engage the tubular member to allow the LDM to move the tubular member vertically.

22. The drilling rig of claim 21 wherein the tubular member engaged by the LDM clamp and LDM slip is aligned with the rack of the derrick.

23. The drilling rig of claim 1, wherein the CDU comprises:

a lower seal positioned within a lower seal housing, the lower seal positioned to seal against an upper end of an th tubular member clamped by the LDM;

a circulation housing mechanically coupled to the lower seal housing, the circulation housing comprising or more fluid inlets, the or more fluid inlets positioned to allow drilling fluid to enter an interior of the circulation housing and flow into the tubular member, thereby defining a lower flow path;

a valve positioned within a valve housing coupled to the circulation housing, a space between the lower seal and the valve within the lower seal housing, the circulation housing, and the valve housing defining a lower chamber;

an outer extension cartridge mechanically coupled to the valve housing;

an inner extension cartridge positioned within the outer extension cartridge and adapted to telescopically slide within the outer extension cartridge;

an upper seal mechanically coupled to the inner extension barrel, the upper seal positioned to seal against a lower end of a second tubular member,

the space between the valve and the upper seal within the valve housing, the outer extension cartridge and the inner extension cartridge defines an upper chamber;

an inverted slip assembly comprising a slip bowl and or more wedges, the or more wedges positioned to grip the second tubular member, the inverted slip assembly coupled to the inner extension drum, and

, the or more linear actuators being positioned to telescopically extend or retract the inverted slip assembly and the upper seal vertically relative to the valve housing.

24, a method, comprising:

positioning a drilling rig at a wellsite, the drilling rig comprising:

a drill floor having a V-shape , a side of the drill floor including the V-shape defining a V-shape side of the drill floor, the V-shape having a V-shape axis defined perpendicular to the V-shape side of the drill floor;

a support structure and a second support structure, the rig floor being supported by the a support structure and the second support structure, the rig floor, the a support structure and the second support structure forming a beam structure, an open space between the a support structure and the second support structure and below the rig floor defining a transverse gallery having a transverse gallery axis, wherein the transverse gallery axis is perpendicular to the V axis;

a mast mechanically coupled to or more of said drilling rig floor, said support structure or said second support structure at or more mast mounting points, said mast comprising a frame having an open side defining a mast V-shaped side, said mast V-shaped side aligned with said V-shaped , said mast comprising or more racks coupled to said frame at said V-shaped side;

a lower drilling rig (LDM) coupled to the mast and vertically movable relative to the mast;

a Continuous Drilling Unit (CDU) mechanically coupled to the LDM;

an Upper Drilling Machine (UDM) coupled to the mast and vertically movable relative to the mast; and

an Upper Mud Assembly (UMA) coupled to the derrick and vertically movable relative to the derrick, the UMA including a drilling mud supply pipe adapted to supply drilling fluid to a tubular member defining an upper flow path gripped by the UDM; and

the drilling rig is used to continuously drill a wellbore.

25. The method of claim 24, wherein:

the UDM includes:

a UDM clamp adapted to engage a tubular member to allow the UDM to rotate the tubular member; and

a UDM slip positioned to engage the tubular member to allow the UDM to move the tubular member vertically;

the LDM includes:

an LDM clamp adapted to engage a tubular member to allow the LDM to rotate the tubular member; and

an LDM slip positioned to engage the tubular member to allow the LDM to move the tubular member vertically; and is

The CDU includes:

a lower seal positioned within a lower seal housing, the lower seal positioned to seal against an upper end of an th tubular member clamped by the LDM;

a circulation housing mechanically coupled to the lower seal housing, the circulation housing comprising or more fluid inlets, the or more fluid inlets positioned to allow drilling fluid to enter an interior of the circulation housing and flow into the tubular member, thereby defining a lower flow path;

a valve positioned within a valve housing coupled to the circulation housing, a space between the lower seal and the valve within the lower seal housing, the circulation housing, and the valve housing defining a lower chamber;

an outer extension cartridge mechanically coupled to the valve housing;

an inner extension cartridge positioned within the outer extension cartridge and adapted to telescopically slide within the outer extension cartridge;

an upper seal mechanically coupled to the inner extension cartridge, the upper seal positioned to seal against a lower end of a second tubular member, a space between the valve and the upper seal within the valve housing, the outer extension cartridge, and the inner extension cartridge defining an upper chamber;

an inverted slip assembly comprising a slip bowl and or more wedges, the or more wedges positioned to grip the second tubular member, the inverted slip assembly coupled to the inner extension drum, and

, the or more linear actuators being positioned to telescopically extend or retract the inverted slip assembly and the upper seal vertically relative to the valve housing.

26. The method of claim 25, wherein continuously drilling comprises:

engaging the th tubular member with the LDM clamp, the LDM slip, and the lower seal;

rotating the th tubular member with the LDM at a speed, the th speed being defined as a drilling speed;

closing the valve;

vertically extending the inverted slip assembly and the upper seal with the linear actuator;

engaging the second tubular member with the UDM clamp and the UDM slip;

lowering the second tubular member into the CDU;

engaging the second tubular member with the inversion slips and the upper seal;

rotating the second tubular member with the UDM at a higher speed than the drilling speed;

flowing fluid through the second tubular member through the upper flow path;

retracting the inverted slip assembly and the upper seal with the linear actuator;

opening the valve;

threadably coupling the th tubular member and the second tubular member;

rotating said th tubular member and said second tubular member with said UDM at said drilling speed;

disengaging the LDM clamp, the LDM slip, the lower seal, the inverted slip, and the upper seal;

moving the LDM vertically upward such that the LDM clamp is aligned with the top of the second tubular member;

engaging the LDM clamp, the LDM slip, and the lower seal to the second tubular member;

rotating the second tubular member with the LDM;

disengaging the second tubular member from the UDM; and

drilling fluid is flowed through the second tubular member through the lower fluid path.

27. The method of claim 26, wherein the second tubular member is joined to the UDM by a drill shaft extension threadably coupled to the upper end of the second tubular member.

28. The method of claim 27, wherein disengaging the second tubular member from the UDM comprises:

engaging the drill shaft extension with the inverted slips and the upper seal; rotating the drill shaft extension with the UDM at a slower speed than the drilling speed;

threadably disengaging the drill shaft extension from the second tubular member;

vertically extending the inverted slip assembly and the upper seal with the linear actuator;

closing the valve; and

disengaging the drill shaft extension from the inverted slips and the upper seal.

Technical Field

The present disclosure relates generally to drilling rigs, and in particular to drilling rig structures for drilling wells in the oil exploration and production industry.

Background

Land-based drilling rigs may be configured to be moved to different locations to drill multiple wells in the same area (conventionally referred to as a wellsite). In some cases, a land-based drilling rig may travel across a drilled well existing at a landed wellhead. Furthermore, derrick placement on land rigs may have an impact on drilling activities. For example, depending on the placement of the derrick on the rig, the existing wellhead may interfere with the location of equipment located on land (e.g., the existing wellhead (s)), and may also interfere with the lifting and lowering of the equipment required for operation.

Disclosure of Invention

The present disclosure provides drilling rig, which may include a drilling rig floor having a V-type , the side of the drilling rig floor including V-type may define a V-type side of the drilling rig floor, V-type may have a V-type axis defined as being perpendicular to the V-type side of the drilling rig floor, the drilling rig may include a th support structure and a second support structure, the drilling rig floor may be supported by a th support structure and a second support structure, the drilling rig floor, a th support structure and the second support structure may form a cross-beam structure, the open space between the th support structure and the second support structure and below the drilling rig floor may define a lateral corridor having a lateral corridor axis, the lateral corridor axis may be perpendicular to the V-type support structure 2 axis, the drilling rig may include UMM type drilling rigs, the UMV-type drilling rig floor may be mechanically coupled to the drilling rig floor at mounting points, the drilling rig floor may include a UMV-type drilling rig floor, the drilling rig floor may be vertically aligned with a drilling rig floor, the drilling rig floor may include a drilling rig floor, and a drilling rig floor may be vertically movable mast assembly may include a drilling rig floor, the drilling rig floor may include a drilling rig floor may be vertically movable rig floor, the drilling rig floor may include a rig floor may be aligned with a rig floor, a drilling rig floor may be aligned with a drilling rig floor, a drilling rig floor may be aligned with a drilling rig floor, a.

The present disclosure also provides methods that may include positioning a drilling rig at a well site, the drilling rig may include a drilling rig floor having a V-type , a side of the drilling rig floor including the V-type may define a V-type side of the drilling rig floor, the V-type may have a V-type axis defined as a V-type side perpendicular to the drilling rig floor, the drilling rig may include a th support structure and a second support structure, the drilling rig floor may be supported by a th support structure and the second support structure, the drilling rig floor, a th support structure and the second support structure may form a cross-beam structure, an open space between the th support structure and the second support structure and below the drilling rig floor may define a transverse gallery axis having a transverse gallery axis, the transverse gallery axis may be perpendicular to the V-type axis, the drilling rig may include a UMV 639 or more mechanically coupled to the drilling rig floor at a rig mounting point 639, the drilling rig floor may be vertically aligned with a drilling rig floor, the drilling rig floor may include a drilling rig floor may be vertically aligned with a drilling rig floor, a drilling rig floor may include a drilling rig floor, a drilling rig floor may be aligned with a drilling rig floor, a drilling rig floor may be aligned with a drilling rig floor, a drilling.

Brief description of the drawings

The disclosure can be best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the proportional dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

Fig. 1-3 depict perspective views of a drilling rig consistent with at least embodiments of the present disclosure.

Fig. 4 depicts a front view of the V-shaped side of the rig of fig. 1-3.

Fig. 5 depicts a front view of the driller's house side of the rig of fig. 1-3.

Fig. 6 depicts a front view of the back of the drill of fig. 1-3.

Fig. 7 depicts a front view of the driller's opposite side of the drilling rig of fig. 1-3.

Fig. 8 depicts a top view of the drilling rig of fig. 1-3.

Fig. 9 depicts a cut-away top view of the support structure of the drilling rig of fig. 1-3.

Fig. 10 depicts a partial side view of the mast and secondary mast of the drilling rig of fig. 1-3.

Fig. 11 depicts a cross-sectional view of a Continuous Drilling Unit (CDU) resulting from at least embodiments of the present disclosure.

Fig. 12-21A depict the drilling rig of fig. 1 at various stages of a continuous drilling operation.

Detailed Description

It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. Of course, these serve only as examples and are not intended to limit the disclosure. Additionally, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

1-10 depict perspective views of a rig 10. the rig 10 may be positioned in a wellsite 5. the wellsite 5 may include or more wellheads 7. in cases, the wellheads 7 may be arranged in a linear fashion along the wellsite 5. each wellhead 7 may be an upper end of a wellbore that extends below the surface, or may represent a location where the rig 10 will drill such a wellbore.

Drilling rig 10 may include a drilling rig floor 12 and or a plurality of support structures 14 may be positioned to support drilling rig floor 12 and other components of drilling rig 10 above ground level, as discussed further below in embodiments support structures 14 may include components that allow drilling rig 10 to travel through well site 5, as discussed further below.

In embodiments, the support structures 14 may be arranged such that the support structures 14 and rig floor 12 form a beam structure, the open space between the support structures 14 and below the rig floor 12 may define at least lateral galleries 16, represented by lateral gallery axes 18 in FIGS. 1-10. in embodiments, the rig 10 may be oriented such that the lateral gallery axes 18 are substantially aligned with the wellheads 7 of the wellsites 5. in such an arrangement, as the rig 10 travels through the wellsite 5 along a line of the wellheads 7 to move, for example and without limitation, from a drilling wellhead 7 to a drilling second wellhead 7, the rig 10 may travel linearly in the direction of the lateral gallery axes 18. since no fixed component of the support structures 14 or rig floor 12 is positioned in the lateral gallery 16, the rig 10 may not interfere with any component of the wellhead 7, for example and without limitation, the Christmas tree 8. in embodiments, as depicted in FIGS. 1-10, the rig 10 may include two support structures 14, which define a single lateral gallery 16, and in , the rig 10 may travel along more lateral gallery axes of the drill 10, and the number of the support structures may avoid interference with the two or more lateral galleries 16, the rig floor 14, and the rig 10 may be arranged along the lateral gallery axes 18.

In embodiments, rig floor 12 may include a V-shape . V-shape may be an open portion of sides of rig floor 12 through which tubular members such as casing, drill pipe or other tools pass when being lifted into rig 10 or lowered out of rig 10. V-shape may be a physical opening in rig floor 12 or may be another designated area of rig floor 12 without other equipment that would impede movement of the tubular members and other tools. embodiments, the tubular members may be introduced into rig 10 using carriage 22 of catwalk system 24. carriage 22 or other corresponding structure (such as a slide) of rig floor 12 may be mechanically coupled to the side of rig floor 12 that includes V-shape . the side is defined as V-shape side 26 of rig floor 12. before the tubular members and other tools are introduced into rig floor 10 through V-shape . catwalk system 24 may be used to store the tubular members and other tools on ground level side 26 in embodiments with vertical ground level 3814, and vertical drill floor 28 may be positioned in a substantially straight line with drill floor supporting V-type 4614, transverse direction of rig floor 12, such vertical boresight system 28 may be positioned between the vertical rig floor 14 and drill floor 14 in a vertical boresight axis 28, such embodiments.

In embodiments , each support structure 14 may be adapted to move between a raised position and a lowered position, hi embodiments, the rig floor 12 and other components of the rig 10 coupled thereto may be moved between a raised position and a lowered position, hi embodiments , when the rig 10 is in operation, the raised position may be used, as depicted in fig. 1-10, such that there is sufficient clearance between the ground level and the rig floor 12 to allow the rig floor 12 to clear any equipment needed for the drilling operation, such as, but not limited to, the BOP 9 positioned on the wellhead 7, hi embodiments , the lowered position may be used when the rig 10 is "assembled" or "disassembled" after or in preparation for transportation.

In embodiments, each support structure 14 may include a lower box 50. the lower box 50 may be in contact with the ground and may support the weight of the support structure 14 and the rest of the rig 10. in embodiments, each support structure 14 may include or more support beams 52. each support beam 52 may be pivotably coupled to the lower box 50 at a lower pivot point 54 and pivotably coupled to the rig floor 12 at an upper pivot point 56. in embodiments, the support beams 52 may form a linkage between the lower box 50 and the rig floor 12 that allows the rig floor 12 to move between a lowered position and a raised position as the support beams 52 pivot relative to the lower box 50 and the rig floor 12. in embodiments, the support beams 52 may be arranged such that the rig floor 12 remains substantially parallel to the ground during the transition between the lowered position and the raised position.

In embodiments, or more cross support beams 58 may extend between the lower box 50 and the rig floor 12 to, for example, but not limited to, maintain the rig floor 12 in a raised position.

In embodiments, support structure 14 may include or more mechanisms for traveling rig 10 through wellsite 5. for example, without limitation, in embodiments, support structure 14 may include a travel actuator 30, as best depicted in FIG. 9. travel actuator 30 may be positioned within lower housing 50. in embodiments, travel actuator 30 may be adapted to lift lower housing 50 off the ground, move rig 10 a small distance, and lower housing 50 to the ground. by repeatedly actuating travel actuator 30 in this manner, rig 10 may be moved through wellsite 5. in embodiments, travel actuator 30 may be used to move rig 10 between wellheads 7. in embodiments, travel actuator 30 may be used to move rig 10 along lateral corridor axis 18. in embodiments, travel actuator 30 may be rotated, allowing travel actuator 30 to move rig 10 in directions other than along lateral corridor axis 18.

In embodiments, the drilling rig 10 may include additional equipment mechanically coupled to the drilling rig floor 12, the support structure 14, or both, for example, in embodiments or more of the driller's house 40 and the choke 42 may be positioned on the drilling rig floor 12 or cantilevered from the drilling rig floor 12. in embodiments, the mud gas separator skid 44 and the stair skid 46 may be mechanically coupled to the drilling rig floor 12 and vertically down from the drilling rig floor 12 to ground level. in embodiments, the hydraulic power unit skid 47 and the accumulator skid 48 may be mechanically coupled to the support structure 14 and may be cantilevered or otherwise supported by the support structure 14. in embodiments, additional equipment including, for example, but not limited to, a mud tank, a treatment tank, a mud makeup apparatus, a compressor, a variable frequency drive, or a drill wire line winder may be coupled to the drilling rig 10. in embodiments, additional equipment coupled to the drilling rig 10 (including, for example, but not limited to, the driller's house 40, the separation tank, the treatment tank, the mud makeup apparatus, the compressor, the variable frequency drive, or the drill line winder may travel through the drilling rig floor 12, or rig floor 12 as well drilling rig floor 12 travels through the rig floor 12, the rig 14, the additional equipment 369, the rig 46, or BOP equipment may travel through the rig floor 48, the rig floor 12, the rig 14, 4935, the rig 14, the additional equipment, the rig 14, or the rig 14.

In embodiments, rig floor 12 may be moved between a raised position and a lowered position by or more hydraulic cylinders in embodiments, the hydraulic cylinders may extend between or more lower housings 50 and rig floor 12 in embodiments, lifting skid 70 may be mechanically coupled to rig 10 in embodiments, lifting skid 70 may include lifting skid mount 72. lifting skid mount 72 may be mechanically coupled to or more in support structure 14. lifting skid 70 may include or more lifting actuators 74 in embodiments, the 856 or more lifting actuators may be hydraulic cylinders coupled to lifting skid mount 72. lifting actuators 74 may be pivotally coupled to lifting skid mount 72. in embodiments, lifting actuators 74 may each be mechanically coupled to or more corresponding lifting points of rig floor 12 by, for example but not limited to, a pinned connection to lifting skid lift actuator 74 may be moved to a lifting skid mount 76 for moving rig floor 12 to a desired lifting rig floor lifting unit 76 or retracting rig floor 70 to a desired lifting rig floor lifting unit lift unit or lifting rig floor may be moved between a desired lifting position and a desired lifting rig floor lowering position for lowering operation of rig floor 38, lifting rig floor 5834, lifting rig floor 99 in 4685 embodiments, lifting skid lift unit may be controlled by, lifting unit , lifting unit lift may be moved between, , 366 and a desired lifting unit lift unit.

Rig 10 may include a mast 100. the mast 100 may be mechanically coupled to a rig floor 12 and/or a support structure 14. in embodiments, the mast 100 may include or more upright structures defining a frame 102 of the mast 100. in embodiments, the cross-section of the mast 100 may be rectangular. in embodiments, the frame 102 of the mast 100 may include an open side defining a mast V-type 0 side 104. in embodiments, the mast V-type 1 side 104 may be substantially open such that tubular members and other tools introduced through the V-type 20 of the rig floor 12 may enter the mast 100 as they are lifted into the rig 10. the mast V-type side 104 may be oriented opposite the V-type axis 28 such that the mast V-type side 104 is aligned with the V-type 20 of the rig floor 12.

In embodiments, the rig 10 may include a racking station 90. the racking station 90 may be mechanically coupled to the derrick 100. the racking station 90 may be used, for example and without limitation, to store tubular members in a vertical position on the rig 10. in embodiments, the racking station 90 may include or more fingerboards 92 positioned to define slots 94 in the racking station 90 into which tubular members may be positioned for storage.

In embodiments , the drilling rig 10 may include a drill rod handler assembly 60. the drill rod handler assembly 60 may include a secondary derrick 62. the secondary derrick 62 may be mechanically coupled to the drilling rig floor 12. in embodiments , the secondary derrick 62 may be mechanically coupled to the derrick 100. in embodiments , the drill rod handler assembly 60 may be positioned on the drilling rig floor 12 at a location corresponding to V-type . the drill rod handler assembly 60 may include a drill rod handler 64. the drill rod handler 64 may include a drill rod gripper 66. the drill rod gripper 66 may be mechanically coupled to the secondary derrick 62 by a drill rod handler arm 67. the drill rod handler arm 67 may be mechanically coupled to the drill rod handler carriage 68. the drill rod gripper 66 of the drill rod handler 64 may be used to grip a tubular member or other tool from the channel system 24 as the tubular member or other tool enters V-type . the drill rod handler 64 may be used to move the drill rod handler arm 66 and the drill rod handler 67 vertically to position the drill rod handler 67 as the tubular member or other tool enters V-type . in embodiments the drill rod handler may be used to position the drill rod handler carriage 66 or other drill rod handler carriage 68 to position a plurality of drill rod handler motors to position a drill string 3590 or other drill string handler such as well as.

In embodiments, the mast 100 may include a rack 106 mechanically coupled to the frame 102. the rack 106 may be positioned on the frame 102 of the mast 100 at a side 104 of the mast V . the rack 106 may extend substantially vertically along the entire length of the mast 100. the rack 106 may be used as part of of a or multiple rack and pinion lift system, as discussed further below.

In embodiments, the mast 100 may be mechanically coupled to the remainder of the rig 10 at or more mast mounting points 108, 110. in embodiments, the mast 100 may be mechanically coupled to the mast mounting points 108, 110 by pin connections in embodiments, the mast 100 may be pivotally coupled to a subset of the mast mounting points 108, 110, such as the mast mounting point 108, such that the mast 100 may be pivotally raised or lowered when assembling or disassembling the rig 10, respectively.

In embodiments, the mast 100 may be constructed of two or more mast subcomponents, depicted in FIGS. 1-10 as mast subcomponents 100 a-d. in embodiments, to transport the mast 100, the mast subcomponents 100a-d may be disengaged from each other and may each be transported individually. in embodiments, as discussed further to , pieces or pieces of equipment coupled to the mast 100 may remain in pieces or pieces of derrick subcomponents 100a-d during transport, for example, but not limited to, reducing the number of loads that need to be transported and reducing the time taken to assemble or disassemble the rig 10. in embodiments, the mast subcomponents 100a-d may be mechanically coupled upon reaching wellsite 5 to form the mast 100. in embodiments, the mast subcomponents 100a-d may be mechanically coupled using, for example, but not limited to, pin connection 114.

In embodiments, or more drilling machines may be mechanically coupled to the derrick 100 and may be used to raise and lower a drill string being used to drill a borehole, to rotate the drill string, to position tubular members or other tools to be added to or removed from the drill string, and to make or break connections between tubular members in embodiments such machines may include a top drive, elevator, or other lifting mechanism.

In embodiments, the drilling rig 10 may include an Upper Drilling Machine (UDM)121, the UDM121 may be used during drilling operations, such as, but not limited to, to raise and lower tubular members, as used herein, tubular members may include drill pipe, drill collars, casing, or other components of a drill string or components added to or removed from a drill string, in embodiments, the UDM121 may include a UDM clamp 123. the UDM clamp 123 may be used, for example, but not limited to, to engage a tubular member during drilling operations. the UDM121 may be adapted to rotate a tubular member engaged by the UDM clamp 123. in embodiments, the UDM121 may include a UDM slip 125. the UDM slip 125 may be positioned to engage a tubular member, such as, but not limited to, to allow the UDM121 to move the tubular member vertically relative to the derrick 100. in embodiments, the UDM121 may include a UDM pinion 127. the UDM pinion may engage a rack 106 of the derrick 100. the UDM 127 may be driven by or more motors, including, such as, but not limited to, hydraulic or electric motors, to move the derrick 100 vertically.

In embodiments, the derrick 100 may include a Lower Drilling Machine (LDM)131, the LDM131 may be used during drilling operations, such as, but not limited to, to raise and lower tubular members As used herein, tubular members may include drill pipe, drill collars, casing, or other components of a drill string or components added to or removed from a drill string, in embodiments, the LDM131 may include an LDM clamp 133. the LDM clamp 133 may be used, such as, but not limited to, to engage a tubular member during drilling operations. the LDM131 may be adapted to rotate a tubular member engaged by the LDM clamp 133. in embodiments, the LDM131 may include an LDM slip 135. the LDM slip 135 may be positioned to engage a tubular member, such as, but not limited to, to allow the LDM131 to move the tubular member vertically relative to the derrick 100. in embodiments, the LDM131 may include an LDM pinion 137. the LDM pinion 137 may engage the rack 106 of the derrick 100. the LDM pinion 137 may be driven by or more motors, including, such as, but not limited to, hydraulic or electric motors, to move the derrick 131 vertically along the derrick 100.

Referring briefly to FIG. 12, in embodiments, the derrick 100 may also include a Continuous Drilling Unit (CDU) 161. the CDU 161 may be mechanically coupled to the upper end of the LDM 131. the construction and operation of the CDU 161 is further described below at .

Referring again to FIG. 2, in embodiments UDM121 and LDM131 may each move independently relative to derrick 100. in embodiments UDM121 and LDM131 may be operated to make and break connections between tubular members during drilling operations (including, for example and without limitation, drilling, tripping, and tripping operations). in embodiments UDM121 and LDM131 may each be positioned such that tubulars supported or gripped by UDM121 or by LDM131 are aligned with the front of derrick 100, and thus with rack 106 of derrick 100.

In embodiments, the derrick 100 may include an Upper Mud Assembly (UMA) 141. UMA 141 may include a drilling mud supply pipe 143 adapted to supply drilling fluid to a tubular member held by the UDM 121. the drilling mud supply pipe 143 may be fluidly coupled to a tubular member held by the UDM121, and may be used, for example and without limitation, to supply drilling fluid to a drill string during portions of a drilling operation. in embodiments, UMA 141 may include a mud assembly pinion 145 (shown in FIG. 12.) the mud assembly pinion 145 may engage the rack 106 of the derrick 100. in embodiments, the mud assembly pinion 145 may be driven by or more motors (including, for example and without limitation, hydraulic or electric motors) to move UMA 141 vertically along the derrick 100. in other embodiments, UMA 141 may be moved by the UDM 121. in other embodiments, UMA 141 may include a trolley wheel positioned on the derrick 100. such a crane may include a trolley wheel.

In embodiments, to disassemble the mast 100 for transport, the components of the mast 100 may be repositioned within the mast 100 such that each component is positioned within a particular mast sub 100a-d, as described below.

In such disassembly operations, any tubular members may be removed from all components of the mast 100. in embodiments, the LDM131 may be lowered into the th mast sub 100 a. in embodiments, the th mast sub 100a may be the lowermost of the mast sub 100 a-d. LDM131 may be lowered using LDM pinion 137. in embodiments, the CDU 161 may be removed from the LDM131 and may be shipped separately from the rest of the mast 100.

In embodiments, the UDM121 may be lowered into the second mast sub 100b, in embodiments, the second mast sub 100b may be the second lowest of the mast sub 100a-d, the UDM121 may be lowered using the UDM pinion 127, in embodiments, the UMA 141 may be positioned within the third well rack component 100c, in embodiments, the third well rack component 100c may be the third lowest of the mast sub 100a-d, in embodiments, the UMA 141 may be positioned using or more of the UDM121, mud assembly pinion 145, or another crane (such as a pneumatic crane).

In embodiments, as discussed herein above, the mast subcomponents 100a-100d of the mast 100 may be disengaged so that each mast subcomponent 100a-100d, including any components of the mast 100 positioned therein, may be transported individually.A mast subcomponent 100a-100d may be transported, for example and without limitation, by a truck-trailer.A th mast subcomponent 100a may be transported with LDM131, a second mast subcomponent 100b may be transported with UDM121, and a third well mast subcomponent 100c may be transported with UMA 141. in embodiments, the length of each mast subcomponent 100a-100d may be selected so that the total weight of the transported portion is within a desired maximum weight.in embodiments, the length of each mast subcomponent 100a-100d may be selected so that its length and weight conforms to or more transportation rules, including, for example and without limitation, allowing load ratings.in embodiments, such an arrangement may allow components that are otherwise too heavy to be transported as a single load to be divided into multiple loads.

In embodiments, once derrick 100 is fully assembled to rig 10, CDU 161 may be mechanically coupled to the upper end of LDM 131. As shown in cross-section in FIG. 11, CDU 161 may include lower seal housing 163. lower seal housing 163 may mechanically couple CDU 161 to LDM 131. lower seal 165 may be positioned within lower seal housing 163 and may be positioned to seal against the upper end of tubular member 200. in embodiments, tubular member 200 may be the uppermost tubular member of a drill string. in embodiments, lower seal 165 may be positioned to seal against tubular member 200, while tubular member 200 is gripped by LDM clamp 133 and or both of LDM slips 135 (not shown in FIG. 11) during drilling operations.

The circulation housing 167 may be mechanically coupled to a valve housing 171. the valve housing 171 houses a valve 173 positioned to separate, when closed, the portion of the interior of the CDU 161 below the valve 173 (defining a lower chamber 175) from the portion of the interior of the CDU 161 above the valve 173 (defining an upper chamber 177.) the lower chamber 175 may be defined between the valve 173 and the lower seal 165 and may be in fluid communication with the inlet 169. in embodiments, the valve 173 may be a flapper valve.

The valve housing 171 may be mechanically coupled to the outer extension barrel 179 may be positioned about the inner extension barrel 181 may be telescopically slidable within the outer extension barrel 179 between a retracted configuration (as shown in FIG. 11) and an extended configuration, as discussed further below at .

The upper end of the inner extension barrel 181 may be mechanically coupled to an inverted slip assembly 183 the inverted slip assembly 183 may include a slip bowl 185 and wedge or wedges 187 positioned to grip a tubular member as discussed in below the inner extension barrel 181 may also be mechanically coupled to an upper seal 189 the upper seal 189 may be positioned to seal against the outer surface of a tubular member held by the inverted slip assembly 183 the upper seal 189 may define the upper end of the upper chamber 177 in embodiments the lower seal housing 163, lower seal 165, circulation housing 167, valve housing 171, valve 173, outer extension barrel 179, inner extension barrel 181, inverted slip assembly 183, and upper seal 189 may define a rotating portion of the CDU 161 and may be rotated as units by rotation of a tubular member held by the inverted slip assembly 183.

In embodiments, CDU 161 may include a non-rotating housing assembly 191 may include a lower housing 193 and an upper housing 195 similar to lower seal housing 163, lower housing 193 may be mechanically coupled to LDM 131. upper housing 195 may be coupled to lower housing 193 by or more linear actuators 197 to move upper housing 195 axially relative to lower housing 193. in embodiments, linear actuators 197 may be hydraulic pistons, electromechanical actuators, or any other suitable device.

In embodiments, the lower seal housing 163, lower seal 165, circulation housing 167, valve housing 171, valve 173, and outer extension drum 179 may be rotatably mechanically coupled to the lower housing 193 in embodiments, the inner extension drum 181, the inverted slip assembly 183, and the upper seal 189 may be mechanically coupled to the upper housing 195 in embodiments, or more bearings may be positioned between components of the rotating portion of the CDU 161 and components of the housing assembly 191.

The upper housing 195 is axially movable between an extended configuration and a retracted configuration to define the extended configuration and the retracted configuration of the CDU 161. As the upper housing 195 moves, the inner extension cylinder 181 moves relative to the outer extension cylinder 179 while maintaining the seal, thereby maintaining the upper chamber 177.

During operation, the tubular member may be inserted into the CDU 161 such that the lower end of the tubular member is positioned above the valve 173 within the upper chamber 177 while the upper housing 195 is in the extended configuration and retained by the inverted slip assembly 183 and the upper seal 189 the upper housing 195 may then be moved axially relative to the lower housing 193 to a retracted configuration pushing the lower end of the tubular member through the valve 173 into the lower chamber 175, in embodiments the lower end of the tubular member may be positioned in contact with the tubular member 200 to form a threaded connection therebetween, likewise, once the connection is broken , the upper housing 195 may be moved to the extended configuration moving the lower end of the upper tubular member from the lower chamber 175 into the upper chamber 177, thus allowing the valve 173 to close and isolating the lower chamber 175 from the upper chamber 177.

In embodiments, as described above, the drilling rig 10 with derrick 100 may be used during normal drilling operations, including for example and without limitation conventional drilling, tripping and tripping or other operations in some such embodiments the UDM121 or LDM131 may be used to raise, position and rotate a drill string in some embodiments the UDM121 or LDM131 may be used to make or break drill pipe connections to add or remove tubular members relative to a drill string with or without the use of UMA 141 and CDU 161, as described below.

In embodiments, the drilling rig 10 may be used during continuous drilling operations in such embodiments, the UDM121, LDM131, UMA 141, and CDU 161 may be used to continuously circulate drilling fluid through the drill string during drilling operations without stopping or slowing rotation of the drill string or penetrating subterranean formations during the addition of additional tubular members to the drill string.

For example, fig. 12-21 depict continuous drilling operations with embodiment of the present disclosure, as described further below.

FIG. 12 depicts the drilling rig 10 during continuous drilling operations while the UDM121 is handling a cyclical phase of the drilling operation, in embodiments, a drill shaft extension 151 may be positioned within the UDM 121. the drill shaft extension 151 may be engaged by a UDM clamp 123 and a UDM slip 125. the drill shaft extension 151 may be coupled to the UMA 141 such that the UMA 141 allows drilling fluid to flow into the drill shaft extension 151, thereby defining an upper flow path As shown in FIG. 12, the drill shaft extension 151 is threadably coupled to an upper end of the drill string 201 such that rotation of the drill shaft extension 151 by the UDM121 is transferred to the drill string 201 and drilling fluid from the UMA 141 is circulated through the drill string 201. in embodiments, such as in embodiments where the drilling rig 10 is used for conventional drilling, the UMA 141 may supply drilling fluid directly to the drill string 201. the UDM121 rotates the drill string 201 at a desired drilling speed and moves down as the drilling fluid penetrates further into the subterranean formation. in this phase, the LDM131 and CDU 161 are not engaged with the drill string 201. in particular, the LDM clamp 135, the slip clamp 133, the slip clamp assembly 161, and the lower flow path is retracted from the upper flow path 169 to the lower flow path of the lower portion of the drilling string 201.

As shown in fig. 13 and 13A, LDM131 may be moved upward to a position where the upper end of drill string 201 is within lower chamber 175 of CDU 161, with drill shaft extension 151 extending through upper chamber 177 and into lower chamber 175 of CDU 161. LDM131 may be moved downward such that this alignment is maintained despite downward movement of drill string 201 and UDM121 during drilling operations.

Once LDM131 is so aligned, LDM131 can begin to rotate LDM clamp 133 and LDM slip 135 at constant speed to match the rotation of drill string 201 (i.e., drilling speed). once the rotation rate is matched, LDM clamp 133 and LDM slip 135 can each be actuated to engage drill string 201. thus, the weight of drill string 201 can be transferred from UDM121 to LDM131 while both engage drill string 201. inversion slip assembly 183 and upper seal 189 can be actuated to engage drill shaft extension 151 and lower seal 165 can be actuated to engage drill string 201, as shown in FIG. 13B. the rotating components of CDU 161 can be rotated by rotation of drill shaft extension 151 at drilling speed. then, the lower flow path can be opened to introduce drilling fluid through inlet 169 into upper chamber 177 and lower chamber of CDU 175 to equalize the pressure therein to the pressure in drill string 201, as shown in FIG. 13C.

The threaded connection between the drill shaft extension 151 and the drill string 201 may then be disconnected as the LDM131 rotates the drill string 201 at drilling speed, the UDM121 may slow the rotation of the drill shaft extension 151, resulting in the disconnection of the threaded connection between the drill string 201 and the drill shaft extension 151, as shown in FIGS. 14 and 14A. the UDM121 may move upward relative to the LDM131 to account for the disconnection of the threaded connection.

The CDU 161 may then be extended sufficiently such that the lower end of the drill shaft extension 151 moves upwardly out of the lower chamber 175 and into the upper chamber 177 of the CDU 161, as shown in fig. 15 and 15A. The valve 173 may be closed, isolating the lower chamber 175 from the upper chamber 177. The upper chamber 177 may be depressurized and the fluid within the upper chamber 177 and the drill shaft extension 151 may be discharged. The inverted slip assembly 183 and upper seal 189 may be disengaged from the drill shaft extension 151 as shown in FIG. 15B. UDM121 is disconnected from drill string 201 and can be moved to a raised position relative to derrick 100 while LDM131 runs a drilling operation, as shown in fig. 16.

Drill pipe handler assembly 60 may move a tubular (defined as the lower drill pipes 203) to be added to drill string 201 into position and allow it to be threadably coupled to the lower end of drill shaft extension 151, as shown in fig. 17 in embodiments, the connection between drill shaft extension 151 and the lower drill pipes 203 may be made up by rotation of drill shaft extension 151 by UDM121 in other embodiments, drill pipe handler assembly 60 may rotate the lower drill pipes 203 relative to drill shaft extension 151.

The UDM121 may be moved downward such that the lower ends of the lower drill rods 203 are inserted into the upper chamber 177 of the CDU 161, as shown in fig. 18 and 18A, the inverted slip assemblies 183 and upper seals 189 may be engaged against the lower drill rods 203, as shown in fig. 18B, the upper flow path through the UMA 141 may be opened, thereby introducing drilling fluid into the upper chamber 177 of the CDU 161 and equalizing the pressure within the upper chamber 177 with the pressure within the lower chamber 175, as shown in fig. 18C.

The CDU 161 may then be partially retracted, extending the lower ends of the lower drill rods 203 into the lower chamber 175 and opening the valve 173, as shown in fig. 19 and 19A.

The UDM121 may be lowered and the CDU 161 may be retracted as the lower drill rods 203 are threadedly coupled to the drill string 201, as shown in fig. 20 and 20A once the threaded connection is complete, the UDM121 may be slowed down to rotate the drill shaft extension 151 and drill string 201 (now including the lower drill rods 203) at the drilling speed, the lower flow path through the inlet 169 may be closed, and drilling fluid may be drained from the upper chamber 177 and lower chamber 175 of the CDU 161, as shown in fig. 20B, the weight of the drill string 201 may be transferred from the LDM131 to the UDM121 while both are engaged, then the UDM121 and CDU 161 may be disengaged from the drill string 201, as shown in fig. 21 and 21A, specifically, the lower slips assembly 135, the slip seal 183 may be added to the drill string 201 to stop the rotation of the drill string 201, and the slip assembly may be repeatedly added to the drill string 201 each time the drill string 201 is rotated.

In embodiments, similar operations may be performed during a drill-down or drill-up operation while maintaining continuous mud circulation or rotation of the drill string.

Those skilled in the art should appreciate that they can readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein.