U.S. patent application number 11/198475 was filed with the patent office on 2006-10-19 for apparatus and method for performing earth borehole operations.
Invention is credited to Thomas Dyer Wood.
Application Number | 20060231268 11/198475 |
Document ID | / |
Family ID | 37114183 |
Filed Date | 2006-10-19 |
United States Patent
Application |
20060231268 |
Kind Code |
A1 |
Wood; Thomas Dyer |
October 19, 2006 |
Apparatus and method for performing earth borehole operations
Abstract
An apparatus for performing earth borehole operations comprising
a base or substructure, a mast mounted on the base, a top drive
mounted on the mast for longitudinal movement therealong, the top
drive having an opening therethrough and a coiled tubing injector
mounted on the mast above the top drive such that coiled tubing
from the tubing injector can pass through the opening in the top
drive, the apparatus being operable to selectively use the top
drive to engage and manipulate a component used in borehole
operations while the coiled tubing injector is substantially
inoperative and selectively operable to use the coiled tubing
injector to inject coiled tubing into an earth borehole while the
top drive is substantially inoperative or alternatively using the
coiled tubing injector to inject coiled tubing into a tubular
string being manipulated by the top drive.
Inventors: |
Wood; Thomas Dyer; (Calgary,
CA) |
Correspondence
Address: |
Browning Bushman P.C.
5718 Westheimer, Suite 1800
Houston
TX
77057-5771
US
|
Family ID: |
37114183 |
Appl. No.: |
11/198475 |
Filed: |
August 5, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11149673 |
Jun 10, 2005 |
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11198475 |
Aug 5, 2005 |
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11107183 |
Apr 15, 2005 |
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11149673 |
Jun 10, 2005 |
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Current U.S.
Class: |
166/379 ;
166/384; 166/77.2; 166/78.1 |
Current CPC
Class: |
E21B 7/02 20130101; E21B
19/22 20130101 |
Class at
Publication: |
166/379 ;
166/384; 166/077.2; 166/078.1 |
International
Class: |
E21B 19/22 20060101
E21B019/22 |
Claims
1. An apparatus for performing earth borehole operations
comprising: a base; a mast mounted on said base; a top drive
mounted on said mast for longitudinal movement therealong, the top
drive having an opening therethrough; and a coiled tubing injector
mounted on said mast above said top drive such that coiled tubing
from said tubing injector can pass through said opening in said top
drive.
2. The apparatus of claim 1, wherein said mast comprises first and
second, spaced frame members, said top drive and said coiled tubing
injector being mounted between said frame members.
3. The apparatus of any of claims 1 or 2, wherein said top drive is
slidably mounted on said mast.
4. The apparatus of claim 3, wherein said mast is provided with
tracks and said top drive slides on said tracks.
5. The apparatus of any of claims 1 or 2, wherein said coiled
tubing injector is carried by said top drive whereby movement of
said top drive moves said coiled tubing injector longitudinally
along said mast.
6. The apparatus of any of claims 1 or 2, wherein said top drive is
moved longitudinally along said mast using a draw works.
7. The apparatus of any of claims 1 or 2, wherein said mast is
provided with tracks and said top drive and said coiled tubing
injector slide on said tracks.
8. The apparatus of claim 6, wherein said draw works is mounted on
said base.
9. The apparatus of claim 6, wherein said draw works is mounted on
said mast.
10. The apparatus of any of claims 1 or 2, wherein said apparatus
further includes a rotary table mounted on said base.
11. The apparatus of any of claims 1 or 2, wherein said coiled
tubing injector is adapted to be selectively latched in a
preselected position on said mast.
12. The apparatus of any of claims 1 or 2, wherein said base
comprises a wheeled structure.
13. The apparatus of any of claims 1 or 2, wherein said mast is
pivotally secured to said base for movement to preselected angles
ranging from horizontal to vertical and at any desired angle
therebetween.
14. The apparatus of any of claims 1 or 2, wherein said coiled
tubing injector includes a lubricator for guiding coiled tubing,
said lubricator telescoping to selectively allow access to said
coiled tubing.
15. The apparatus of any of claims 1 or 2, wherein said top drive
and said coiled tubing injector are selectively operable,
independent of one another, to perform earth borehole operations
with jointed pipe or coiled tubing, respectively.
16. An apparatus for connecting the tubing of a coiled tubing
injector to a bottom hole assembly comprising: a base; a mast
mounted on said base; a top drive mounted on said mast for
longitudinal movement therealong, said top drive having an opening
therethrough; a coiled tubing injector mounted on said mast above
said top drive such that coiled tubing from said coiled tubing
injector can pass through said opening in said top drive; and a
rotary table mounted on said base, said rotary table being operable
to engage and manipulate a first component of a bottom hole
assembly, said top drive being operable to engage and manipulate a
second component of a bottom hole assembly, said top drive and said
rotary table being cooperatively operable to make up a complete
bottom hole assembly, said coiled tubing injector being selectively
operable to move coiled tubing through said opening in said top
drive into and out of engagement with said complete bottom hole
assembly.
17. The apparatus of claim 16, wherein said mast comprises first
and second, spaced frame members, said top drive and said coiled
tubing injector being mounted between said frame members.
18. The apparatus of any of claims 16 or 17, wherein said top drive
is slidably mounted on said mast.
19. The apparatus of claim 18, wherein said mast is provided with
tracks and said top drive slides on said tracks.
20. The apparatus of any of claims 16 or 17, wherein said coiled
tubing injectors carried by said top drive whereby said movement of
said top drive moves said coiled tubing injector longitudinally
along said mast.
21. The apparatus of any of claims 16 or 17, wherein said top drive
is moved longitudinally along said mast using a draw works.
22. The apparatus of any of claims 16 or 17, wherein said mast is
provided with tracks and said top drive and said coiled tubing
injector slide on said tracks.
23. The apparatus of claim 22, wherein said draw works is mounted
on said base.
24. The apparatus of claim 22, wherein said draw works is mounted
on said mast.
25. The apparatus of any one of claims 16 or 17, wherein said
apparatus further includes a rotary table mounted on said base.
26. The apparatus of any of claims 16 or 17, wherein said coiled
tubing injector is adapted to be selectively latched in a
preselected position on said mast.
27. The apparatus of any one of claims 16 or 17, wherein said base
comprises a wheeled structure.
28. The apparatus of any of claims 16 or 17, wherein said mast is
pivotally secured to said base for movement to preselected angles
ranging from horizontal to vertical and at any desired angle
therebetween.
29. The apparatus of any of claims 16 or 17, wherein said coiled
tubing injector includes a lubricator for guiding coiled tubing,
said lubricator telescoping to selectively allow access to said
coiled tubing.
30. The apparatus of any of claims 16 or 17, wherein said top drive
and said coiled tubing injector are selectively operable,
independent of one another, to perform earth borehole operations
with jointed pipe or coiled tubing, respectively.
31. A method of performing earth borehole operations comprising:
providing a base; providing a mast mounted on said base; providing
a top drive mounted on said mast for longitudinal movement
therealong, said top drive being operable to engage and manipulate
components used in earth borehole operations, said top drive having
an opening therethrough; providing a coiled tubing injector mounted
on said mast above said top drive such that coiled tubing from said
injector can pass through said opening in said top drive; providing
a rotary table on said base; selectively using said top drive to
engage and manipulate a component used in earth borehole operations
while said coiled tubing injector is substantially inoperative; and
selectively using said coiled tubing injector to inject coiled
tubing into said earth borehole while said top drive is
substantially inoperative, said coiled tubing passing through said
opening in said top drive.
32. The method of claim 31, including engaging a first component of
a bottom hole assembly by said rotary table.
33. The method of claim 31, including engaging a second component
of a bottom hole assembly by said top drive.
34. The method of claim 33, comprising operating said rotary table
and said top drive to connect said first and second components of
said bottom hole assembly together.
35. The method of claim 34, comprising further operating said
rotary table and said top drive to successively connect components
of a bottom hole assembly to make up a complete bottom hole
assembly.
36. The method of claim 35, comprising disengaging said top drive
from said complete bottom hole assembly while suspending said
complete bottom hole assembly from said rotary table.
37. The method of claim 36, comprising moving said coiled tubing
injector to a position such that coiled tubing passing through said
opening in said top drive can engage said complete bottom hole
assembly.
38. The method of claim 37, comprising disengaging said rotary
table from said bottom hole assembly whereby said complete bottom
hole assembly can be lowered using said coiled tubing injector to
perform earth borehole operations.
39. The method of claim 31, wherein said earth borehole operations
comprise drilling with coiled tubing.
40. The method of claim 39, wherein said drilling comprises
directional drilling.
41. The method of claim 31, wherein said earth borehole operations
comprise drilling with conventional jointed drill pipe using said
top drive.
42. The method of claim 31, where said drilling comprises
directional drilling.
43. The method of claim 31, wherein said earth borehole operations
comprise using coiled tubing in completion operations.
44. The method of claim 31, wherein said earth borehole operations
comprise running coiled tubing as production tubing.
45. The method of claim 31, wherein said earth borehole operations
comprise running casing using said top drive.
46. The method of claim 31, wherein said earth borehole operations
comprise conducting completion operations using said top drive.
47. The method of claim 31, wherein said earth borehole operations
comprise running production tubing using said top drive.
48. A method of performing earth borehole operations comprising:
providing a base; providing a mast mounted on said base; providing
a top drive mounted on said mast for longitudinal movement
therealong, said top drive being operable to engage and manipulate
a component used in earth borehole operations, said top drive
having an opening therethrough; providing a coiled tubing injector
mounted on said mast above said top drive such that coiled tubing
from said injector can pass through said opening in said top drive;
using said top drive to engage and manipulate a component used in
earth borehole operations; and using said coiled tubing injector to
inject coiled tubing into said component through said opening in
said top drive, while said top drive is manipulating said
component.
49. The method of claim 48, wherein said component is a string of
casing.
50. The method of claim 48, wherein said component is a string of
tubing.
51. The method of claim 48, wherein said component is a string of
drill pipe.
52. The apparatus of any of claims 1, 2, 16 or 17, wherein said top
drive is moved longitudinally along said mast using a hydraulic
cylinder system.
53. An apparatus for performing earth borehole operations
comprising: a base; a mast mounted on said base; a coiled tubing
injector mounted on said mast for longitudinal movement therealong;
a top drive mounted on said mast for longitudinal movement
therealong, said top drive being mounted below said coiled tubing
injector, said top drive having a first position wherein said
coiled tubing injector can pass through said top drive and a second
position wherein coiled tubing from said coiled tubing injector can
pass alongside said top drive.
54. The apparatus of claim 53, wherein said mast comprises first
and second, spaced frame members, said first and second spaced
frame members being provided with first and second mast tracks
extending longitudinally along said first and second frame members,
said top drive being movable along said first and second
tracks.
55. The apparatus of claim 54, wherein there are first and second
spur tracks operatively connected to said first and second mast
tracks, respectively, said first and second spur tracks extending
transversely to said first and second mast tracks, respectively,
said top drive being movable from said mast tracks to said spur
tracks.
56. The apparatus of claim 55, further including a switching
mechanism to switch said top drive from said mast tracks to said
spur tracks.
57. The apparatus of claim 54, wherein said top drive is carried by
a frame, said frame having a first side and a second side, said
first side carrying a first roller assembly engaging said first
mast track, said second side carrying a second roller assembly
engaging said second mast track whereby said frame can move
longitudinally along said mast tracks.
58. The apparatus of claim 57, wherein said top drive has a first
frame position generally centrally of said frame between said first
and second sides and a second frame position proximate one of said
first and second sides.
59. The apparatus of claim 58, wherein said top drive is suspended
from said frame by first and second bails, said first and second
bails being pivotally secured to said frame and to said top
drive.
60. The apparatus of claim 59, wherein there is a mechanical
linkage between at least one of said first and second bails and
said frame to effect pivoting of said at least one of said bails
whereby said top drive is moved from said first to said second
frame position.
61. The apparatus of claim 60, wherein said mechanical linkage
comprises a piston cylinder arrangement.
62. The apparatus of claim 1, wherein said coiled tubing injector
is mounted on a carrier frame, said carrier frame being
longitudinally movable along said mast, said coiled tubing injector
being pivotally mounted on said carrier frame whereby said coiled
tubing injector can be moved from a first position to a second
position.
63. The apparatus of claim 62, wherein in said first position said
coiled tubing injector is generally parallel to said mast and in
said second position said coiled tubing injector is transverse to
said mast.
64. The apparatus of claim 63, wherein in said second position said
coiled tubing is substantially perpendicular to said mast.
65. The apparatus of claim 62, wherein said carrier frame includes
a shaft, said coiled tubing injector being affixed to said
shaft.
66. The apparatus of claim 65, wherein said mast comprises first
and second spaced frame members and said carrier frame comprises a
first pillow block operatively connected to said first frame member
and a second pillow block operatively connected to said second
frame member, said shaft being rotatably journaled in said first
and second pillow blocks.
67. The apparatus of claim 62, wherein there is a first
piston/cylinder assembly interconnecting said coiled tubing
injector and a portion of said carrier frame which is not rotatable
relative to said mast, said first piston/cylinder assembly being
operative to move said coiled tubing injector from said first
position to said second position.
68. The apparatus of claim 67, wherein there is a second piston
cylinder assembly interconnecting said coiled tubing injector and a
second portion of said frame which is not rotatable relative to
said mast.
69. The apparatus of claim 62, wherein said carrier frame includes
a shaft, such coiled tubing injector being rotatable on said
shaft.
70. The apparatus of claim 69, wherein said mast comprises first
and second spaced frame members and said carrier frame comprises a
first pillow block operatively connected to said first frame member
and a second pillow block operatively connected to said second
frame member, said shaft being fixedly secured in said first and
second pillow blocks.
71. The apparatus of claim 62, wherein said coiled tubing injector
is connected to a reel of coiled tubing by said coiled tubing, said
reel being rotatable in a first direction to pivot said coiled
tubing injector from said first position toward said second
position, said reel being rotatable in a second direction to permit
said coiled tubing injector to move from said second position to
said first position.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The application is a continuation-in-part of U.S. patent
application Ser. No. 11/149,673 filed Jun. 10, 2005, which in turn
is a continuation-in-part of U.S. application Ser. No. 11/107,183
filed Apr. 15, 2005, and for APPARATUS AND METHOD FOR PERFORMING
EARTH BOREHOLE OPERATIONS, both of which are incorporated herein in
their entirety for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to apparatus for performing earth
borehole operations such as drilling, and in particular to
apparatus which can use both coiled tubing and jointed-pipe.
[0004] 2. Description of Prior Art
[0005] The use of coiled tubing (CT) technology in oil and gas
drilling and servicing has become more and more common in the last
few years. In CT technology, a continuous pipe wound on a spool is
straightened and pushed down a well using a CT injector. CT
technology can be used for both drilling and servicing.
[0006] The advantages offered by the use of CT technology,
including economy of time and cost are well known. As compared with
jointed-pipe technology wherein typically 30-45 foot straight
sections of pipe are threadedly connected one section at a time
while drilling the wellbore, CT technology allows the continuous
deployment of pipe while drilling the well, significantly reducing
the frequency with which such drilling must be suspended to allow
additional sections of pipe to be connected. This results in less
connection time, and as a result, an efficiency of both cost and
time.
[0007] However, the adoption of CT technology in drilling has been
less widespread than originally anticipated as a result of certain
problems inherent in using CT in a drilling application. For
example, because CT tends to be less robust than jointed-pipe for
surface-level drilling, it is often necessary to drill a surface
hole using jointed-pipe, cement casing into the surface hole, and
then switch over to CT drilling. Additionally, when difficult
formations such as rock are encountered down-hole, it may be
necessary to switch from CT drilling to jointed-pipe drilling until
drilling through the formation is complete, and then switch back to
CT drilling to continue drilling the well. Similarly, when it is
necessary to perform drill stem testing or coring operations to
assess conditions downhole, it may again be necessary to switch
from CT drilling to jointed-pipe drilling and then back again.
Finally, a switch back to jointed pipe operations may be necessary
to run casing into the drilled well. In short, in CT drilling
operations it is generally necessary for customers and crew to
switch back and forth between CT drilling rig and jointed-pipe
conventional drilling rigs, a process which results in significant
down-time as one rig is moved out of the way, and another rig put
in place.
[0008] Another disadvantage of CT drilling is the time consuming
process of assembling a (bottom-hole-assembly (BHA)--the components
at the end of the CT for drilling, testing, well servicing, etc.),
and connecting the BHA to the end of the CT. Presently, this step
is performed manually through the use of rotary tables and
make-up/breakout equipment. In some instances, top drives are used
but the CT injector and the top drive must be moved out of each
others way, i.e., they cannot both be in line with the borehole.
Not only does this process result in costly downtime, but it can
also present safety hazards to the workers as they are required to
manipulate heavy components manually.
[0009] In U.S. Publication 2004/0206551 there is disclosed a rig
adapted to perform earth borehole operations using both CT and/or
jointed-pipes, the CT injector and a top drive being mounted on the
same mast, the CT injector being selectively moveable between a
first position wherein the CT injector is in line with the mast of
the rig and hence the earth borehole and a second position wherein
the CT injector is out of line with the mast to allow operations
using the top drive involving jointed pipe.
SUMMARY OF THE INVENTION
[0010] In one aspect, the present invention provides an apparatus
for performing earth borehole operations comprising a base or
substructure, a mast mounted on the base, a top drive mounted on
the mast for longitudinal movement therealong, the top drive having
an opening therethrough, and a coiled tubing injector mounted on
the mast above the top drive such that coiled tubing from the
tubing injector can pass through the opening in the top drive.
[0011] In another aspect, the present invention provides an
apparatus for connecting the tubing of a coiled tubing injector to
a bottom hole assembly comprising a base or substructure; a mast
mounted on the base; a top drive mounted on the mast for
longitudinal movement therealong, the top drive having an opening
therethrough; a coiled tubing injector mounted on the mast above
the top drive such that coiled tubing from the coiled tubing
injector can pass through the opening in the top drive; a rotary
table mounted on the base, the rotary table being operable to
engage and manipulate a first component of a bottom hole assembly,
the top drive being operable to engage and manipulate a second
component of a bottom hole assembly, the top drive and the rotary
table being cooperatively operable to make up a complete bottom
hole assembly, the coiled tubing injector being selectively
operable to move coiled tubing through the opening in the top drive
and into and out of engagement with the complete bottom hole
assembly.
[0012] In still another aspect of the present invention, there is
provided a method of performing earth borehole operations
comprising: providing a base; providing a mast mounted on the base;
providing a top drive mounted on the mast for longitudinal movement
therealong, the top drive being operable to engage and manipulate
components used in earth borehole operations, the top drive having
an opening therethrough; providing a coiled tubing injector mounted
on the mast above the top drive such that coiled tubing from the
injector can be passed through the opening in the top drive;
providing a rotary table mounted on said base; selectively using
the top drive to engage and manipulate a component(s) used in earth
borehole operations while the coiled tubing injector is
substantially inoperative; and selectively using the coiled tubing
injector to inject coiled tubing into the earth borehole while the
top drive is substantially inoperative, the coiled tubing passing
through the opening in the top drive.
[0013] In another aspect, the present invention provides a method
of performing earth borehole operations comprising: providing a
base; providing a mast mounted on the base; providing a top drive
mounted on the mast for longitudinal movement therealong, the top
driving being operable to engage and manipulate a component used in
earth borehole operations, the top driving having an opening
therethrough; providing a coiled tubing injector mounted on the
mast above the top drive such that coiled tubing from the injector
can pass through the opening in the top drive; using the top drive
to engage and manipulate a component used in earth borehole
operations; and using the coiled tubing injector to inject coiled
tubing into said component through said opening in said top
drive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a partial, side elevational view of an apparatus
according to the present invention.
[0015] FIG. 2 is a partial, side elevational view of a second
embodiment of the apparatus of the present invention.
[0016] FIG. 3 is a partial, side elevational view of the apparatus
shown in FIG. 1, wherein the top drive is manipulating a tubular
component.
[0017] FIG. 3A is a view taken along the lines 3A-3A of FIG. 3.
[0018] FIG. 4 is a partial, side elevational view of another
embodiment of the apparatus of the present invention.
[0019] FIG. 5 is a partial, side elevational view of the apparatus
of the present invention shown in FIG. 4 with the coiled tubing
injector in a position to perform earth borehole operations and
shows, in phantom, positioning the mast of the apparatus at an
angle to the horizontal to effect off-vertical earth borehole
operations.
[0020] FIG. 6 is a side, partial elevational view showing a bottom
hole assembly being made up using the apparatus of the present
invention.
[0021] FIG. 7 is a side, partial elevational view showing another
embodiment of the apparatus of the present invention wherein the
hydraulic ram system is used as the lifting mechanism for the top
drive.
[0022] FIG. 7A is a view taken along the lines 7A-7A of FIG. 7.
[0023] FIG. 8 is a partial, side elevational view of another
embodiment of the apparatus of the present invention showing the
top drive positioned directly below the coiled tubing injector on a
track system secured to the mast.
[0024] FIG. 9 is a partial, side elevational view of the embodiment
shown in FIG. 8 but with the top drive moved laterally on a spur
track system such that the top drive is laterally displaced from
the coiled tubing injector.
[0025] FIG. 10 shows a top, detailed view of a split block
arrangement for carrying the top drive.
[0026] FIG. 11 is an elevational view of a top drive-split block
arrangement shown in FIG. 10.
[0027] FIG. 12 is a top plan view, similar to FIG. 10 showing how
the top drive can be moved laterally relative to the mast.
[0028] FIG. 13 is an elevational view of the arrangement shown in
FIG. 12.
[0029] FIG. 14 is a partial, side elevational view of another
embodiment of the apparatus of the present invention.
[0030] FIG. 15 is a rear elevational view of the embodiment shown
in FIG. 14.
[0031] FIG. 16 is a view similar to FIG. 13 showing the coiled
tubing injector pivoted 90.degree. from the position shown in FIG.
13.
[0032] FIG. 17 is a rear elevational view of the embodiment shown
in FIG. 16.
[0033] FIG. 18 is a side elevational view of another embodiment of
the apparatus of the present invention.
[0034] FIG. 19 is a rear elevational view of the embodiment shown
in FIG. 18.
[0035] FIG. 20 is a view similar to FIG. 18 but showing the coiled
tubing injector and the gooseneck being rotated 90.degree. relative
to the view shown in FIG. 18.
[0036] FIG. 21 is a rear elevational view of the embodiment shown
in FIG. 20.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Referring first to FIG. 1, the apparatus of the present
invention is seen to comprise a mast, shown generally as 10, and a
base shown generally as 12. Mast 10, as shown particularly with
reference to FIG. 3A, is comprised of a pair of spaced elongate
frame members 14 interconnected at the top by a crown 16. Although
not shown, mast 12 is pivotally connected to base 12 for reasons
described hereafter. However, it is not necessary that mast 10 be
pivotally connected to base 12, i.e., it could be fixedly attached,
if desired. As shown, base 12 comprises a wheeled carrier or
trailer 18 providing a generally centrally located platform 20, the
wheeled carrier 18 having a tongue 22 which can be attached to a
motorized vehicle such that the trailer 18 can be moved from one
location to another. It will be appreciated that the wheeled
carrier 18 can be self propelled and even further that the base can
comprise a stationary structure as, for example, a skid or the like
which can be raised and placed on a trailer or other transport
vehicle for movement to another site, if desired. It will also be
appreciated that the apparatus of the present invention could be
mounted on an offshore platform via a skid or other substructure on
while the mast and other components are mounted. Wheeled trailer 18
also provides a second, rear platform 26 on which is mounted a
rotary table 24. Rear platform 22 provides a work surface 26 for
workers to manipulate various downhole components into and out of
the rotary table and to perform other normal operations in
conjunction with earth borehole operations such as drilling,
workover, servicing, etc.
[0038] Rotatably mounted on the platform 18 is a spool 28 upon
which is wound a length of coiled tubing 30. Spool 28 can be
rotated in clockwise and counterclockwise directions using a
suitable drive assembly (not shown). Also located on platform 18 is
an engine 27 and a hydraulic tank 29 for storage of hydraulic fluid
used in operating the various hydraulic components of the
apparatus, e.g., motors, hydraulic cylinders, etc. As is well
known, most of the components of the apparatus can be operated
hydraulically, electrically or, in some cases, pneumatically. The
coiled tubing 30 extends up to a gooseneck or guide 32 supported in
a well-known manner. The gooseneck 32 is attached to a coiled
tubing injector 34 which, as shown in FIG. 3A, is positioned
between members 14 forming mast 10. As is well-known to those
skilled in the art, coiled tubing injector 34 typically comprises a
series of blocks, sprockets or like grippers driven by endless
chains or belts, shown in phantom as 39, and which grab the coiled
tubing 30 and force it downwardly in the direction of arrow A when
it is being injected into a well and move it upwardly in the
direction of arrow B when it is being removed from the well.
[0039] As shown in FIGS. 1 and 3A, a top drive 36 is mounted on
mast 10 between members 14 for longitudinal movement therealong in
either the direction of arrow A or arrow B. Typically, top drive 36
is mounted on a track system, indicated as 15, which is affixed to
members 14. It will be recognized, however, that top drive 36 could
be suspended in other fashions other than the track system 15 such
that it could be longitudinally moved along mast 10. Top drive 36
is moved longitudinally along mast 10 by a hoisting system
comprised of a winch or draw works mounted on platform 18 and one
or more cables 40 which run through a crown block sheave assembly
16a located at the top of mast 10. The cables 40 pass through or by
coiled tubing injector 34 and are attached to top drive 36 in a
well-known manner whereby draw works 38 can selectively raise top
drive 36 upwardly along mast 10 or lower top drive 36 downwardly
along mast 10, i.e., in the directions of arrows A and B,
respectively. In the embodiment shown in FIG. 1, the top drive
serves as an elevator for the coiled tubing injector 34, in that
movement of the coiled tubing injector 34 longitudinally along the
mast 10 is effected by movement of the top drive 36. In this
regard, as noted, the cables 40 run through or alongside coiled
tubing injector 34 and are attached to the top drive 36 in the
well-known manner. It will be understood however that, while more
complicated, coiled tubing injector 34 could be moved independently
along mast 10 by a separate draw works or winch. However, the
apparatus of the present invention is vastly simplified by using
the top drive 36 as an elevator to effect longitudinal movement of
coiled tubing injector 34.
[0040] As seen in FIG. 1, top drive 36 has an opening 37 extending
longitudinally therethrough for a purpose to be described
hereafter. While the opening 37 has been described as extending
longitudinally through the top drive 36, it is conceivable that a
top drive unit could be designed such that the opening was not
through the top drive but rather was an opening in the form of a
slot on the side of the top drive. Obviously, such a top drive
would be more complicated in construction and might have to
accommodate lateral movement such that when the top drive was being
used it was aligned with the vertical axis of the borehole, but
when the tubing injector was being used, the tubing issuing
therefrom would also be aligned with the vertical axis of the
borehole. Accordingly, the phrases "longitudinally therethrough",
"therethrough", or "through" with respect to the opening in the top
drive is intended to include slots or other formations in the top
drive which permit the coiled tubing injector to be positioned
above the top drive and the coiled tubing maintained in line with
the vertical axis of the wellbore. A suitable top drive for use in
the apparatus of the present invention is a Foremost Model F-100T.
The Foremost Model F-100T is a hydraulic top drive system and is
commercially available. As in the case with other top drive
systems, the Model F-100T is provided with hydraulically actuated
bails to assist in picking up or laying down tubulars and includes
a hydraulically actuated tong assembly mounted on the top drive to
assist in breakout/make-up of the drill string or other tubular
downhole strings.
[0041] It will be appreciated that when, as in the embodiment shown
in FIG. 1, top drive 36 is serving as an elevator for coiled tubing
injector 34, provision could be made to have a platform, cradle or
the like upon which coiled tubing injector 34 would rest, the
platform in turn resting on top drive 36. In any event, it will be
appreciated that there are a variety of ways in which the coiled
tubing injector 34 can be positioned above top drive 36, such that
top drive 36 can serve as an elevator for top drive 34. For
example, while as shown in FIG. 1 coiled tubing injector 34 and top
drive 36 are basically adjacent one another, it is contemplated
that some axial spacing could be accommodated, if necessary,
consistent with having enough longitudinal length along mast 10 for
top drive 36 to act independently when necessary. Such a situation
would occur, for example, when top drive 36 was being used to drill
a surface borehole, run casing, etc. In any event, it will be
appreciated that with coiled tubing injector 34 positioned above
top drive 36, and with top drive 36 having an opening 37 extending
longitudinally therethrough, coiled tubing 30 from coiled tubing
injector 34 can be passed through top drive 36 in which event top
drive 36 would be basically inoperative save for its function as
serving as an elevator for coiled tubing injector 34.
[0042] Turning now to FIG. 2, there is shown another embodiment of
the present invention, wherein the coiled tubing injector 34 is
mounted on the crown of the mast 10 such that it is not
longitudinally movable along the mast 10, but is still above top
drive 36 such that, as in the case of the embodiment shown in FIG.
1, coiled tubing 30 from injector 34 passes through the opening 37
in top drive 36.
[0043] The present invention provides a universal rig which can
selectively handle and run different types of pipe, coiled tubing,
and other earth borehole equipment thereby eliminating the need for
two rigs--one rig to use a top drive in the conventional manner and
a separate coiled tubing injector unit to perform coiled tubing
operations. Thus, in the embodiments shown in FIGS. 1 and 2, the
coiled tubing injector 34 is being used to manipulate coiled tubing
30, the coiled tubing 30 passing through the top drive 36, the top
drive 36 being basically in an inoperative position vis-a-vis
manipulating tubular components, components of bottom hole
assemblies or the like. However, and as noted above, in the
embodiment of FIG. 1, top drive 36 does serve the purpose of being
an elevator for coiled tubing injector 34.
[0044] Turning now to FIG. 3, there is shown an embodiment of the
present invention wherein the coiled tubing injector 34 is
basically in an inoperative position while the top drive 36 is
being operated to manipulate tubular components. In the embodiment
shown in FIG. 3, the coiled tubing injector 34 is moved to the
crown 16 of the mast 10 and is held in that position by a latching
or locking mechanism as, for example, one or more pins 43 (see FIG.
3A) which are operatively mounted in mast 10 and which can be
selectively operated, electrically, hydraulically or in any other
suitable fashion, to engage coiled tubing injector 34 or a cradle
therefor and hold it in that position. It will also be understood
that a plurality of such latching or locking mechanisms can be
spaced longitudinally along mast 10 such that coiled tubing
injector 34 can be held at a variety of desired, longitudinally
spaced locations along mast 10. It will also be appreciated that
provision could be made to use a screw mechanism extending
longitudinally along members 14 which could selectively engage or
disengage injector 34 to continuously or incrementally move coiled
tubing injector 34 along mast 10 rather than having longitudinally
spaced latching mechanisms such as the use of pins 43. In any
event, with coiled tubing injector 34 temporarily locked in the
position shown in FIG. 3, i.e., at crown 16, the top drive 36 can
now perform operations typically performed by a top drive such as,
for example, manipulating a tubular component such as casing 42
brought in through the V-door 44 as is common in typical oilfield
operations. Although not shown, it will be appreciated that the
apparatus of the present invention would be provided with elevators
and other components normally used to manipulate downhole
components, e.g., pipe, as for example, to grip the pipe or other
downhole component and move it to a position where it could be
engaged and subsequently manipulated by the top drive. Thus, using
the apparatus of the present invention in the manner depicted in
FIG. 3, the tubing injector 34 would be inoperative while top drive
36 would be operative. This ability to selectively use the top
drive and the injector independently of one another is clearly
advantageous in terms of saving cost and time.
[0045] With reference now to FIG. 4, there is shown a slightly
different embodiment wherein the draw works 38 is mounted on the
mast 10, the cables 40 running through the crown block 16a in the
crown 16 and down to the top drive 36. It will be appreciated that
in cases, such as the embodiment shown in FIG. 4, wherein the draw
works 38 is mounted on the mast, the draw works could be removably
mounted, carried on a trolley, hingedly attached or the like, such
that, for transportation purposes, the draw works could basically
be moved to a position that it did not extend above the mast when
the mast was lowered to the horizontal, transportation position. As
shown in FIG. 4, extending from coiled tubing injector 34, is a
telescoping lubricator 44, lubricator 44 facilitating connection or
disconnection of coiled tubing 30 with a bottom hole assembly. As
is well known to those skilled in the art, lubricator 44 can be
extended or contracted using a lubricator winch (not shown).
[0046] Referring now to FIG. 5, there is shown still another,
modified embodiment of the apparatus shown in FIG. 1 wherein the
draw works 38, as in the case of the embodiment shown in FIG. 4, is
mounted on the mast 10. In the embodiment shown in FIG. 5, the top
drive 36 and the injector 34 have been moved to the lowermost
position, i.e., adjacent rotary table 24, and in this position, top
drive 36 would be essentially inoperative and coiled tubing
injector 34 would be operative to perform downhole operations such
as drilling, workovers, etc. Additionally, and as can be seen, mast
10 can be pivoted relative to the base 12 by a pivoting assembly
(not shown) to a position depicted in phantom in FIG. 5. Thus, it
can be seen that the mast 10 can be lowered off vertical to operate
at any operating angle between the horizontal and vertical to
permit off-vertical drilling. It would also be understood that in
cases where off-angle well operations were being performed,
reorientation of the rotary table and other component would have to
be accommodated. Additionally using a pivoting connection between
the mast 10 and the base 12 allows the mast 10 to be lowered to a
substantially horizontal position for purposes of moving the
apparatus to another location if base 12 comprises a wheeled
carrier which is either self-propelled or can be pulled by a
motorized vehicle, a skid or the like, etc.
[0047] As noted above, the apparatus of the present invention is
universal in the sense that the same rig carries a coiled tubing
injector to manipulate coiled tubing and a top drive to manipulate
jointed pipe or other downhole components, the injector and the top
drive being selectively, independently operable to perform their
customary functions. Additionally, the universal nature of the
apparatus of the present invention is attested to by the fact that
when the top drive is being used to manipulate a downhole
component, e.g., a string of pipe, such as casing, tubing, drill
pipe, etc., the coiled tubing injector can be simultaneously used
to inject coiled tubing through the top drive into the string of
pipe to perform an operation as, for example, freeing the pipe
string if it is stuck or to some other downhole operation.
[0048] The present invention also provides an efficient apparatus
to cooperatively use the coiled tubing injector and the top drive.
In this regard and referring to FIG. 6, the top drive 36 is shown
in a position displaced axially up from the rotary table 24, the
injector being positioned at the crown as shown in FIG. 3. In the
embodiment shown in FIG. 6, the rotary table 24 is suspending a
downhole motor 50 on the end of which is connected to a drill bit
52. As can be seen, the threaded box end 54 of the downhole motor
50 (or a component attached to the downhole motor 50), is in a
position to receive the threaded pin 56 of a second downhole
component 58 which can be a part of a bottom hole assembly or
alternatively, a conventional tubular member. To connect pin 56
with box 54, top drive 36 is lowered until pin 56 is received in
box 54. At this point, with the rotary table 24 holding the
downhole motor 50 fixed against either rotation or longitudinal
movement, top drive 36 can be rotated to thread pin 56 into box 54.
Alternatively, it will be understood that top drive 36 could be
used to hold component 58 against rotation while it was slowly
being lowered and the rotary table 24 could be used to rotate the
downhole motor 50 which again would cause threaded engagement
between pin 56 and box 54. As noted, in the embodiment shown in
FIG. 6, component 58 could be part of a string of pipe wherein a
plurality of joints of pipe are successively connected together,
the portion of the pipe string suspended in the rotary table 24
being released and lowered as each successive joint of pipe is
connected whereby eventually the entire string is lowered into the
borehole. FIG. 6 also depicts a method of making up and connecting
a complete bottom hole assembly to the end of the coiled tubing
from the coiled tubing injector 34. Thus with the assembly shown in
FIG. 6, once a complete bottom hole assembly, e.g., drill bit,
downhole motor, drill collars, logging equipment, sensors, etc., is
made up, the end of the coiled tubing and the uppermost member of
the complete bottom hole assembly could be operatively engaged
using intergaging latching mechanisms whereby the coiled tubing
could be latched into the uppermost member of the complete bottom
hole assembly and, when the bottom hole assembly is retrieved
unlatched, if desired.
[0049] Referring now to FIGS. 7 and 7A, there is shown an
embodiment of the present invention wherein, as an alternative,
telescoping hydraulic cylinder systems are used to move the top
drive longitudinally along the mast. The apparatus shown in FIGS. 7
and 7A might be utilized when the mast 10 was unusually long, e.g.,
on an offshore platform and in a situation where the top drive 36
was manipulating longer strings of jointed pipe that would result
in greater loading that might make a draw works lifting system such
as shown in the embodiments described above, impractical or at
least require a larger winch, more and heavier cables, etc. As can
be seen from FIG. 7, the system depicted in FIGS. 7 and 7A has no
draw works. Additionally, the base 12 has support legs 60 located
generally under platform 36 to support the extra weight occasioned
by the hydraulic cylinder system employed and any additional
loading from the mast, pipe being handled, etc. It would be
appreciated that the leg 60 could be selectively extended and
retracted as desired. The hydraulic cylinder systems shown
generally as 62 can be made in a four-stage cylinder design
comprised of cylinders 64, 66, 68 and 70, as which can be seen, are
telescopically received into one another such that when all the
hydraulic cylinders are in their lower most position, they are all
received in lower cylinder 64. It is well known to those skilled in
the art, that the cylinder systems would be operated using suitable
pumps, hoses, accumulators (are not shown) well known to those
skilled in the art. The hydraulic cylinder systems 62 are mounted
on a platform 72 formed on base 12. It will be understood that with
the use of the hydraulic cylinders and the increased weight, and if
the base 12 was part of a wheeled carrier, as described above, the
various portions of the base 12, particularly platform 72 would be
built to accommodate the additional weight and the downward force
exerted on the base 12 when the cylinder systems were in a lifting
position such as shown in FIG. 7. As a practical matter, the
apparatus shown in FIGS. 7 and 7A is more ideally suited to use on
a base or sub-structure such as on an offshore platform that can
easily accommodate heavy loads or downward forces. However, for
purposes only of depicting the use of a hydraulic cylinder
system(s) as a lifting or hoisting device for the top drive 36, the
hydraulic cylinder system 62 has been shown as mounted on a wheeled
carrier.
[0050] As can be seen particularly with reference to FIG. 7A, there
could be two of such hydraulic cylinder systems 62, one each
positioned adjacent, generally on the inside, of members 14 forming
mast 10. Referring then to FIG. 7, the uppermost cylinders 70 are
connected to plates 80 that in turn are generally releasably
connected to top drive 36. As shown, plates 80 on top drive 36 are
connected, via a nut and bolt arrangement or some other selectively
releasable mechanism, to a flange 82 connected to coiled tubing
unit 34. In this configuration, movement of the hydraulic cylinder
systems 62 would effect movement of both the coiled tubing unit 34
and the top drive 36. However, if the nut and bolt combinations 81
were removed, top drive 36 could now be moved independently of
coiled tubing injector 34 by the hydraulic cylinder systems 62 and,
for example, coil tubing unit 34 could be latched or locked to the
uppermost portion of the mast 10 below the crown 16 as, for
example, by latching pins 43 such as shown in FIG. 3a.
[0051] As noted above, the system of the present invention
positions the coiled tubing injector in the mast above the top
drive such that coiled tubing issuing from the coiled tubing
injector passes through the top drive. As further noted above, the
coiled tubing need not move directly through any opening in the top
drive but can move in slots or other openings along the side of the
top drive. It is also contemplated that the top drive, albeit
normally positioned below the coiled tubing injector, could be
moved to one side or another in a lateral or transverse direction
relative to the mast such that the coiled tubing injector remained
in line with the wellbore while the top drive was out of alignment
with the wellbore. Thus, the coiled tubing injector and the top
drive could be temporarily in a side-by-side arrangement. This
arrangement is particularly useful in relatively small rigs using
relatively large diameter coiled tubing, e.g., 3''. It will be
understood, as described above, that normally a lubricator (see
FIG. 4) will be employed when coiled tubing injector is connected
to a bottom hole assembly. Referring then to FIGS. 8 and 9, there
is shown one embodiment of the present invention wherein the coiled
tubing injector can be releasably, fixedly positioned at a desired
point along the mast and the top drive parked or moved laterally
relative to the coiled tubing injector such that coiled tubing
issuing from the coiled tubing injector passes alongside the top
drive into the earth borehole. Each of frame members 14 of mast 10
is provided with a mast track 100 upon which coiled tubing injector
39 and top drive 36 travel longitudinally therealong. Each of mast
tracks 100 has operatively connected thereto a spur track or rail
102 which extends transversely from mast tracks 100 to platform 26
or at least some distance laterally displaced from mast tracks 100.
As shown in FIG. 8, top drive 36 is in the position acting as an
elevator for coiled tubing injector 39 carried on top drive 36, the
combination of the coiled tubing injector 39 and top drive 36 being
positioned generally half way along the frame members 14 forming
mast 10. As was described above, top drive 36 is free to move
longitudinally along mast tracks 100 substantially from rotary
table 24 to a desired upper position when coiled tubing injector 39
is positioned and releasably fixed in mast 10 proximate crown
16.
[0052] Referring now to FIG. 9, coiled tubing injector 39 is shown
as being releasably, fixedly held in mast 10 in a manner described
above, while top drive 36 is now positioned in the lower portion of
mast 10 but laterally displaced from mast 10, coiled tubing
injector 39 and the axis 106 of the wellbore. To accomplish this,
coiled tubing injector 39 is releasably fixed in mast 10 at the
location shown in FIG. 9. Top drive 36, as described, can move
downwardly to a point 107 where spur tracks 102 operatively
intersect mast tracks 100. At this point, a switching mechanism 104
is activated to divert a trolley or the like on which top drive 36
is sitting onto spur tracks 102 such that top drive 36 now moves
downwardly but tranversely to mast tracks 100 and can then be
parked or located at a position where it is out of alignment with
the wellbore axis 106. As shown, top drive 36 has been moved
relatively close to work surface 26 but it is apparent that it
could be positioned higher from the position shown in FIG. 9,
indeed even at least partially in the framework of mast 10, and
still remain out of alignment with the axis 106 of the wellbore. In
any event, once the top drive 36 is moved laterally relative to
coiled tubing injector 39, coiled tubing injector 39 can then
inject coiled tubing 30 through rotary table 34 and into the
wellbore, the coiled tubing passing alongside top drive 36. It will
also be appreciated that in the event coiled tubing injector 39 is
provided with a separate hoisting mechanism as previously
described, it could be moved along mast 10 independently of any
movement of top drive 36. In any event, top drive 36 still serves
as an elevator for coiled tubing injector 39 which can be
positioned at a desired location in the mast 10 first, following
which the top drive, if desired, can be moved into a laterally
displaced position as shown in FIG. 9. The terms "operatively
connected," "operatively intersect" or similar term with respect to
the spur tracks 102 and mast tracks 100 is intended to mean that
the two track systems are interrelated to the extent that the top
drive 36 can be switched from mast tracks 100 to spur tracks 102 or
vice versa.
[0053] Switching mechanism 104 can be any one of well known
switching mechanisms used in track conveying systems to selectively
switch a trolley or similar conveying device moving along a first
track system to a second track system. Such switching systems can
be mechanical, electromechanical, pneumatic, etc. It will also be
appreciated that such switching mechanisms can be activated
manually or automatically such that when, in this case, top drive
36 reaches a certain position, i.e., at the juncture or
intersection of spur tracks 102 and mast tracks 100, the switching
system has been set in an automatic mode to move the top drive from
mast tracks 100 to spur tracks 102.
[0054] It is well known in the art that top drives used in oil and
gas drilling and well servicing operations are commonly carried by
a so-called integrated split block arrangement. In a split block
arrangement, a frame having laterally spaced side members is
provided with one or more sheaves on each of the spaced side
members, each of the sheaves being connected by cables to a
suitable crown block. The use of these split block arrangements
reduces stack-up as is common in simple traveling block assemblies.
Such a split block arrangement is ideally suited for use in the
present invention to carry the top drive, the coiled tubing
injector being positioned on a platform, cradle or the like which
would rest on the top drive. In this manner, the split block
assembly essentially forming part of the top drive, as described
above, would act as an elevator for the coiled tubing injector.
Typical of split block arrangements used in conjunction with top
drives is the T75/T100 series of top drives manufactured and sold
by TESCO Corporation as can be seen at www.tescocorp.com.
[0055] Referring now to FIGS. 10-13, there is shown a split block
assembly for use in carrying the top drive used in the present
invention. Frame members 14 of mast 10 are provided with
longitudinally extending tracks 108 and 110. A generally
rectangular frame F shown as 110 comprises a first side frame
member 112, a second, laterally spaced side frame member 114, a
first cross frame member 16 and a second, laterally spaced cross
frame member 118, members 112, 114, 116 and 118 forming a generally
rectangular opening in frame F. Pivotally attached to frame members
118 and 116 is a bail 120. Bail 120 is also pivotally attached to
top drive 36 as shown at 122. A piston-cylinder assembly 124 has
one end of the cylinder pivotally attached as at 125 to frame
member 118, the pivot point 125 being laterally displaced toward
side member 112 relative to the pivot point 121. Reciprocally
extending out of the cylinder of piston-cylinder assembly 124 is a
piston rod 126 which has one end pivotally attached at 122 to bail
120.
[0056] Side member 112 has attached thereto sheaves 130 and 132
while side member 110 has attached thereto sheaves 134 and 136.
Cables 138, 140, 142 and 146 extend from sheaves 130, 132, 134 and
136, respectively, up to a crown block assembly (not shown) as is
well known to those skilled in the art. Thus, by movement of the
cables 138-146, frame F can be moved longitudinally along tracks
108 and 110 and hence longitudinally along the mast 10 formed by
frame members 14. To this end, roller assemblies 160 and 162 are
attached to side frame member 112, while roller assemblies 164 and
166 are attached to side frame 110. As shown, roller assemblies 160
and 162 engage track 108 while roller assemblies 164 and 166 engage
track 109.
[0057] As shown in FIGS. 10 and 11, top drive 36 is suspended below
frame F so as to be positioned generally centrally between side
frame members 112 and 114, i.e., in a position generally in line
with the wellbore axis 106.
[0058] Referring now to FIGS. 12 and 13, the top drive 36 is shown
as being displaced laterally off of the axis of the wellbore 106.
To accomplish this, hydraulic piston-cylinder assembly 124 is
activated to retract piston 126 which results in bail 120 pivoting
around pivot point 121 moving top drive 36 toward track 108.
Piston-cylinder assembly 124 can be hydraulic, pneumatic and it
will be appreciated that any number of mechanisms can be used to
move bail 120 and hence top drive 36 between the positions shown in
FIGS. 11 and 13, i.e., from a position where top drive 36 is
generally over center of the axis 106 of the wellbore to a
position, as shown in FIG. 13, where it is moved laterally with
respect to the axis 106. While the use of only one piston-cylinder
assembly 124 is shown, as a practical matter two such assemblies
would be used, one being attached to cross member 118 as shown, the
other being attached to cross member 116. It will be apparent that
piston-cylinder assembly 124 can be attached to frame F on the side
nearest track 109 such that top drive 36 would now be moved to the
left of wellbore axis 106 as viewed in FIG. 13. The arrangement
shown in FIGS. 11 and 13 is as seen from the V-door side of the
drilling rig (see FIG. 3). Although perhaps somewhat more
complicated, an arrangement similar to that shown in FIGS. 11-13
could be used to move the top drive laterally either towards the
V-door or towards the trailer upon which spool 28 is mounted.
[0059] Referring now to FIGS. 14-17, there is shown an embodiment
of the present invention wherein the coiled tubing injector can be
moved to the top of the mast and pivoted at least 90.degree. so as
to provide more vertical working space in the mast when the top
drive is in use. The apparatus, shown generally as 200, comprises a
mast shown generally as 202 which as seen in FIG. 15 is comprised
of a pair of spaced, elongate frame members 204 and 206
interconnected at the top by a crown 208 carrying a crown block
assembly as described above and as is well known in the art.
Preferably, mast 202 is pivotally connected to a base 210, e.g., in
the form of a wheeled trailer, such that mast 202 can be pivoted to
a generally horizontal position for transportation purposes.
Mounted on wheeled trailer 210 is a reel 212 of coiled tubing from
which coiled tubing 214 can be played out. Coiled tubing 214 passes
through a guide or gooseneck 216 and then into coiled tubing
injector 218.
[0060] As seen particularly in FIGS. 14 and 15, top drive 220 is
located generally midway of mast 202, coiled tubing 214 being
injected via coiled tubing injector 218 through a rotary table
shown generally as 222, into a wellhead, tubing 214 passing through
top drive 220 as described above.
[0061] Coiled tubing injector 218 is mounted on a carrier frame
shown generally as 224, carrier frame 224 comprising a pair of
pillow blocks 226 and 228 which are operatively connected to frame
members 204 and 206, respectively. Thus, as in the other
embodiments described above, coiled tubing injector 218 by means of
frame 224 can move longitudinally along mast 202 on suitable tracks
or the like mounted to the frame members 204, 206. Coiled tubing
injector 218 is secured to or rotatably mounted on a shaft 230, one
end of which is received in pillow block 226, the other end being
received in pillow block 228. In the case where coiled tubing
injector 218 is fixedly secured to shaft 230, shaft 230 would be
rotatably journaled in pillow blocks 226 and 228, suitable bearings
being provided as is known to those skilled in the art.
Alternatively, if coiled tubing injector 218 is rotatably mounted
on shaft 230, then shaft 230 could be fixedly secured in pillow
blocks 226 and 228. In either event, coiled tubing injector 218 is
pivotally secured to frame 224. In the embodiment shown, coiled
tubing injector 218 is fixedly secured to shaft 230.
[0062] A pair of pistons/cylinder assemblies 232, 234, which can be
hydraulic, are interconnected between coiled tubing injector 218
and pillow blocks 226 and 228, respectively. As can be seen, with
respect to piston/cylinder assembly 232, piston rod 235 is
pivotally connected at 236 by a clevis or other suitable connector
to coiled tubing injector 218. The other end of the piston/cylinder
assembly 232 is likewise pivotally connected as at 237 to pillow
block 226 or for that matter any other portion of carrier frame 224
which is not rotatable or pivotable relative to mast 202. For
example, if coiled tubing injector 218 was rotatably mounted on
shaft 230 such that shaft 230 was fixedly secured in pillow blocks
226 and 228, then the piston/cylinder assemblies could be secured
to shaft 230. As can be seen in FIG. 14, piston cylinder assemblies
232 and 234 are off-center with respect to the long axis of coiled
tubing injector 218. Accordingly, if piston rod 235, shown in its
fully extended position in FIGS. 14 and 15, is now retracted, there
will be a vector of force generally in the direction of arrow A
which will tend to pivot coiled tubing injector 218 around an axis
passing through shaft 230. The end result is depicted in FIGS. 16
and 17 wherein coiled tubing injector 218 has been pivoted such
that it is now substantially perpendicular to mast 202, i.e., to
elongate frame members 204, 206. As can be seen in FIGS. 16 and 17,
with piston cylinder assemblies 232, 234 retracted, coiled tubing
injector 218 has been moved 90.degree. from a position where the
coiled tubing injector 218 and hence coiled tubing 214 passing
therethrough is substantially in line with rotary table 222 and
hence the wellhead to a position, as shown in FIGS. 16 and 17,
wherein the coiled tubing injector 218 is substantially
perpendicular to an axis passing through rotary table 222.
[0063] As can also be seen from FIGS. 16 and 17, by pivoting coiled
tubing injector 218 to the position shown, top drive 220 now has
additional vertical space above the rotary table 222. This allows
mast 202 to be more compact in terms of its height. In this regard
it will be appreciated that, depending upon the size of coiled
tubing injector 218, the arrangement shown in FIGS. 14-17 permits
another 2 to 18 feet of vertical head space in mast 202 allowing
top drive 220 to move to a greater height in mast 202 than would be
possible if coiled tubing injector 218 was confined to the position
shown in FIGS. 14 and 15. Ideally, the pivot axis of coiled tubing
injector 218 is as far up as practical, i.e., towards the top of
coiled tubing injector 218, so as to achieve the maximum vertical
head space in mast 202.
[0064] Suitable piston/cylinder assemblies useful in the embodiment
described in FIGS. 14-17 and methods of connecting the same to
suitable sources of hydraulic or pneumatic power are well known to
those skilled in the art and need not be described in any detail
here.
[0065] Referring now to FIGS. 18-20, there is shown a variation of
the embodiment of the invention depicted in FIGS. 14-17, wherein
the coiled tubing injector can be moved from a position where the
coiled tubing injector is in line with the rotary table/wellhead to
a position where the coiled tubing injector is out of line
substantially 90.degree., with e.g., the wellhead. In the
embodiment shown in FIGS. 18-21, the reel 212 of coiled tubing in
conjunction with the coiled tubing 214 is used to rotate coiled
tubing injector 218 from the position shown in FIG. 18 to the
position shown in FIG. 20. In this regard, coiled tubing injector
218, as in the case of the embodiment shown in FIGS. 14-17, is
pivotally mounted on a frame 224 which in turn is longitudinally
movable along the length of mast 202. In the position shown in
FIGS. 18 and 19, coiled tubing injector 218 is in operation, coiled
tubing 214 being played off of reel 212 through top drive 220 and
into the wellhead through rotary table 222. In this situation, and
as will be appreciated, reel 212 is rotating in a clockwise
direction as indicated by arrow B.
[0066] Turning now to FIGS. 20 and 21, once it is desired to rotate
coiled tubing injector 218 from a position in line with the
wellhead, i.e., through rotary table 222, to the position shown in
FIGS. 20 and 21, the coiled tubing 214 which is held or can be held
by any convenient means in coiled tubing injector 218, is now
reeled back onto reel 212, reel 212 now rotating in a
counterclockwise direction as indicated by arrow C. In this manner,
the coiled tubing injector 218, secured to shaft 230 which in turn
is rotatably journaled in journal boxes 226 and 228, will now be
caused to rotate around the axis passing through shaft 230 to the
position shown in FIGS. 20 and 21. At this point, top drive 220 can
then be moved to the desired location in mast 220, to manipulate a
piece of jointed pipe 240 or other tubular member.
[0067] It will be appreciated that in the embodiment shown in FIGS.
14-17, the piston cylinder assemblies 232, 234 can be used to lock
coiled tubing injector into the position shown in FIGS. 16 and 17
by methods well know to those skilled in the art. In the case of
the embodiments shown in FIGS. 18-21, a locking pin, as described
above, or other latching mechanism can be used to hold coiled
tubing injector 218 in the position shown in FIGS. 16 and 17.
Indeed, it will be appreciated that any number of techniques and
apparatuses can be used to maintain coiled tubing injector in the
pivoted positions shown in FIGS. 16 and 20.
[0068] While two methods of pivoting coil tubing injector 218 have
been described, it will be apparent to those skilled in the art
that other devices such as rotary actuators, gearing arrangements,
winch systems, etc., can be employed.
[0069] The "carrier frame" on which coiled tubing injector 218 is
pivotally mounted can comprise any assemblage of components which
alone or together with other operating mechanisms will (a) allow
coiled tubing injector 218 to be pivoted, and (b) allow coiled
tubing injector 218 to be moved longitudinally along the mast.
[0070] As thus seen from the description above, the apparatus of
the present invention can be used in a manner wherein only the top
drive is operative, the coiled tubing injector being positioned,
for example, at a point above the top drive, e.g., at the top of
the mast adjacent the crown and being inoperative. Alternatively,
the top drive can be moved to a lowered position on the mast, e.g.,
at or near the rotary table with the coiled tubing injector being
carried by the top drive, the coiled tubing injector continuously
injecting tubing into the earth borehole to perform a variety of
operations. In this latter mode, the top drive is essentially
inoperative save for the fact that it carries the coiled tubing
injector and can still serve as an elevator for the coiled tubing
injector. In any event all in embodiments, the coiled tubing
injector, the top drive and the rotary table are on axes that are
substantially coincident or can be made coincident with the
wellbore.
[0071] The word "base" or "substructure" as used herein is intended
to mean any structure, be it portable or fixed, whether on land or
offshore, to which the mast can be fixedly, pivotally or removably
attached, which will support the mast and the attendant equipment
used in the apparatus of the present invention, including the
coiled tubing spool, attendant motors, winches or draw works, and
any other equipment commonly used either with (a) coiled tubing
injectors, or (b) top drives.
[0072] The apparatus of the present invention can be used to
accomplish numerous different earth borehole operations. In the
case of employing the coiled tubing injector, the apparatus can be
used to drill using downhole mud motors, such drilling being both
directional and straight hole. Additionally, coiled tubing can be
used in various completion operations such as fracturing;
acidizing; cleanouts; fishing operations; using coiled tubing as a
velocity string, etc. The coiled tubing can also be run as
production tubing. With respect to typical top drive operations,
conventional drilling can be done, casing can be run, and
completion operations as described above with respect of coiled
tubing can also be accomplished. Additionally, the top drive can be
used to run conventional production tubing.
[0073] In general, the apparatus of the present invention permits
every earth borehole operation that can be done in oil and gas well
drilling using either a top drive or a coiled tubing unit.
[0074] A distinct advantage of the apparatus of the present
invention when compared with prior art, so-called universal systems
such as disclosed in U.S. Publication 2004/0206551, is the ability
to perform simultaneous operations with both the coiled tubing
injector and the top drive. In this regard, in the prior art
universal systems it is necessary, when using the top drive, to
move the coiled tubing injector laterally out of alignment from the
borehole and vice versa. With the apparatus of the present
invention, since the coiled tubing injector remains positioned in
line with the top drive and the borehole, in the event, for
example, that operations with the top drive are being performed,
e.g., running casing, and the casing sticks, using the apparatus of
the present invention, coiled tubing can be run down through the
top drive into the casing to assist in freeing the casing. It will
be apparent that other situations can occur where it would be
necessary to quickly inject coiled tubing down through the top
drive and through a tubular string or other downhole component
being manipulated by the top drive to effect some downhole
operation. This, of course, cannot be accomplished with the prior
art, so-called universal systems since, as noted, only one of the
top drive or the coiled tubing injector can be positioned in
alignment with the wellbore at any given time.
[0075] In the above description, the word "mounted" has been used
with respect to the interrelationship between various components of
the apparatus as, for example, the relation of the mast to the top
drive and/or the coiled tubing injector. It is to be understood
that, as used herein, the word "mounted", or variants thereof, in
addition to its usual meaning, is intended to include meanings such
as "positioned", "positioned on", "carried by", "carried on",
"carried", "sitting on", "resting on", or any other similar term.
In other words, the word "mounted", or variants thereof, is not
necessarily limited to meaning "affixed", "affixed to", "attached
to", "attached", "secured to" or other words or phrases carrying a
similar meaning. Thus, for example, references in the description
above to the coiled tubing injector being "mounted on the mast" are
intended to include situations wherein the coiled tubing injector
is positioned adjacent to the mast or positioned relative to the
mast, all with the goal of achieving a scenario wherein the coiled
tubing injector, when injecting coiled tubing, is above the top
drive such that coiled tubing from the tubing injector can pass
through the opening in the top drive from a position above the top
drive.
[0076] It will be understood, that the present invention is not
limited to the use in oilfield operations but can be used in water
well drilling, mining operations, in drilling injection wells, etc.
Also, as noted above, the apparatus of the present invention is not
limited to land earth borehole operations but can be used, as well,
on offshore drilling and production platforms.
[0077] The foregoing description and examples illustrate selected
embodiments of the present invention. In light thereof, variations
and modifications will be suggested to one skilled in the art, all
of which are in the spirit and purview of this invention.
* * * * *
References