Modular racker system for a drilling rig

The systems, devices, and methods described herein relate to a modular racker system for a drilling rig. The modular racker includes transportable modules including a lower track module comprising a drilling rig floor that includes a lower track arranged and configured to accommodate a lower carriage. The lower track is permanently fixed to the drilling rig floor so as to form a part of the drilling rig floor and is transportable as part of the drilling rig floor. An upper track module comprises a fingerboard and an upper track arranged and configured to accommodate an upper carriage moveable along the upper track. The upper track is permanently fixed to the fingerboard and is transportable in a connected configuration. The lower and upper track modules are attachable to a racker column module.

TECHNICAL FIELD

The present disclosure is directed to systems, devices, and methods for efficiently assembling and disassembling at least a portion of a drilling rig. More specifically, the present disclosure is directed to systems, devices, and methods utilizing a modular column pipe racker system on a drilling rig that may be efficiently assembled or disassembled.

BACKGROUND OF THE DISCLOSURE

The exploration and production of hydrocarbons require the use of numerous types of tubulars also referred to as pipes. Tubulars include, but are not limited to, drill pipes, casings, tubing, risers, and other threadably connectable elements used in well structures. The connection of “strings” of joined tubulars or “drill strings” is often used to drill a wellbore and, with regards to casing, prevent collapse of the wellbore after drilling. These tubulars are normally assembled in groups of two or more commonly known as “stands.”

Tubular handling systems, also known as racker systems, on drilling rigs are often used to receive tubulars, manipulate them about the rig, assist in the makeup or breakdown of tubular stands, introduce them for connection into the drill string, receive them from the drill string, and perform other tubular manipulations. These racker systems can be large, complex structures with many components and parts that enable them to move the stands to a desired location and to vertically store them in the derrick or mast. The derrick or mast may include a storing structure commonly referred to as a fingerboard. Fingerboards typically include a plurality of horizontally elongated support structures or “fingers” each capable of receiving a plurality of stands.

Land-based mobile drilling rigs are utilized to drill wells at a first location, and then are often moved to a new second location to drill additional wells. The time period for tearing down a rig, transporting it and setting it up in a new location can vary between days and weeks. However, any downtime of the drilling rig results in high costs with little return. In order to minimize this loss in potential revenue, efficient rig tear down and setup are desirable. Current column pipe racker assemblies are not utilized on the land-based mobile drilling rigs and are confined to permanent drilling rig installations in the offshore. Because of their many large components and pieces, their installation requires the use of many cranes and take a relatively large amount of time. The large components, complex installation requirements and lengthy time for installation result in column rackers utilized on fixed drilling installations and Mobile Offshore Drilling Units (MODU). What is needed is a racker system that is more easily torn down and setup and designed to work with land-based mobile drilling rigs.

The present disclosure is directed to systems and methods that overcome one or more of the shortcomings of the prior art.

DETAILED DESCRIPTION

The systems, devices, and methods described herein relate to a drilling rig apparatus that includes a modular racker system. The modules of the racker system connect together and disconnect in a manner that simplifies the setup and the tear down of the racker system when the drilling rig apparatus is to be moved to a new location. The modules may be moved as a part of the drilling rig apparatus from one drilling location to another drilling location, or may be moved from one drilling rig apparatus to a separate other drilling rig apparatus. Since the racker apparatus comprises modules, the setup and tear down may be accomplished in a minimal amount of time, decreasing down time required between moves. In addition, because the racker system is modular, one module may replace a worn or unusable module in a minimal amount of time, without requiring extensive disassembly of a whole racker system. This may reduce the amount of time required for repairs and, likewise, may increase productivity.

This disclosure discusses components that are permanently fixed together to form a module of the racker system. As used herein, the term “permanently fixed” means that the components are mechanically fixed or maintained together as an assembly and are intended to stay fixed or maintained together during assembly, disassembly, and/or operation of the racker system or drilling rig. The components may be in either direct contact or indirect contact. The term “permanently fixed” does not mean that the components are unable to be disassembled for other purposes such as repair of worn or broken elements, for permanent takedown, cleaning, refurbishing, recycling, or other purposes.

FIG. 1is a schematic of a side view an exemplary drilling rig apparatus100according to one or more aspects of the present disclosure. In some examples, the drilling rig apparatus100may form a part of a land-based, mobile drilling rig. The drilling rig apparatus100may have a drillfloor size of about 35×35 feet, although larger and smaller rigs are contemplated. In some embodiments, the drilling rig apparatus100may have a drillfloor size of less than approximately 1540 square feet. In other embodiments, the drilling rig apparatus100may have a drillfloor size of less than approximately 1720 square feet.

The drilling rig apparatus100shown inFIG. 1includes rig-based structures102and a modular racker system104that operates on the rig-based structures102. The rig-based structures102include, for example, a foundational chassis or rig frame (not shown), a mast106, and a v-door172into the drilling rig apparatus100. The v-door172may be arranged to receive tubulars or stands introduced to the drilling rig apparatus100. In an embodiment, the mast106is disposed over and about well-center107and supports a plurality of drilling components of a drilling system, shown here as a top drive109and its components disposed and moveable along a support column111. Other drilling components are also contemplated.

This embodiment includes an offline mousehole164that may be used to assemble tubulars into stands at a location spaced apart from the well-center107so as to not interfere with drilling at the well-center107. In some embodiments, the mousehole164is located above a shallow hole below a rig floor101that is offline from well-center107, where individual tubulars may be assembled together into stands, e.g. a plurality, such as three tubulars together that are then racked in the fingerboard108for later use or storage. The racker system104is described in greater detail below.

A rig control system161may control the racker system104and other rig components, while also communicating with sensors disposed about the drilling rig apparatus100. The rig control system161may evaluate data from the sensors, evaluate the state of wear of individual tubulars or stands, and may make recommendations regarding validation of tubulars for a particular use as a part of a drilling operation. In some embodiments, the rig control system161may be disposed on the rig floor101, such as in a driller's cabin, may be disposed in a control truck off the rig floor101, or may be disposed elsewhere about the drilling site. In some embodiments, the rig control system161is disposed remote from the drilling site, such as in a central drill monitoring facility remote from the drill site.

A catwalk162forms a part of the drilling rig apparatus100and may be directly attached to or disposed adjacent the rig floor101. The catwalk162allows the introduction of drilling equipment, and in particular tubulars or stands, to the v-door172of the drilling rig apparatus100. In some embodiments, the catwalk162is a simple, solid ramp along which tubulars may be pushed or pulled until the tubular can be grasped or secured by the upper tubular interfacing element105of the racker system104. In other embodiments, the catwalk162is formed with a conveyer structure, such as a belt-driven conveyer that helps advance the tubulars toward or away from the drilling rig apparatus100. Other embodiments include friction reducing elements, such as rollers, bearings, or other structures that enable the tubulars to advance along the catwalk toward or away from the v-door172. It should be noted that where land rigs utilize catwalks, offshore rigs utilize conveyors to transport tubulars from the pipe deck to the rig floor101. Therefore, it should be understood that description of the present disclosure use in a land rig may also be utilized in an offshore rig.

FIG. 2is a schematic of top view of the exemplary drilling rig apparatus100according to one or more aspects of the present disclosure.FIG. 2illustrates the fingerboard108and other portions of the racker system104, the stands176, fingers132forming a part of the fingerboard108, an iron roughneck170, the mousehole164, and the well-center107, all as generally described above. The iron roughneck170may be used to connect and disconnect tubulars or stands at either or both of the well-center107and the mousehole164. A passageway168may extend between opposing sides of the fingerboard108between the v-door172and the well-center107. The racker system104may travel along the passageway168indicated by the arrow inFIG. 2to manipulate tubulars or stands between the fingerboard108, the mousehole164, the well-center107, and the v-door172, and it may travel laterally to a position, such as a parking position, out of the passageway and out of the pathway between well-center107and the v-door172.

FIGS. 3 and 4show the racker system104in greater detail. They include an upper track module112, a racker column module114, and a lower track module116. InFIG. 3, the upper track module112, the racker column module114, and the lower track module116are shown connected in place for operation, whileFIG. 4shows the upper track module112, the racker column module114, and the lower track module116in an exploded condition. The modules may be separated from one another for transport to a new location while still substantially maintaining their own respective assembled states. In some embodiments, however, the modules may still require some level of packing or unpacking, such as folding or collapsing to a more compact state for transport, and unfolding or extending for reuse. Because of this, the modules may also be easily and quickly interchanged with other similar modules, such as by including quick release components to attach and retain modules to each other, and quick connectors to permit simple “plug n' play” with electrical and hydraulic connectors. This may help expedite repairs, because a replacement module may be introduced in place of an older worn or broken module, and the worn or broken module may be removed and entirely fixed offline while the new module is used to keep the racker system104and the drilling rig apparatus100in operation. In another embodiment, the replacement module is swapped in during transport of the modules from one rig or rig site to another.

Referring now toFIGS. 4 and 5, the upper track module112includes, for example, the fingerboard108, upper rails120, an upper carriage that includes an upper cart housing122and an upper cart drive124, a rotational union126for the column structure, and a festoon system128.

The fingerboard108is a holding or storage area for stands that have been or will be used to build the drill string. These stands may be stored in the fingerboard108until they are used or broken down for removal from the drilling rig apparatus100. The fingerboard108includes an outer support frame130having a plurality of individual fingers132extending in a parallel direction and cantilevered from the support frame130. The upper portions of the stands may be inserted between the fingers132and thereby held in place, in a substantially vertical position for storage. As can be seen, in this embodiment, the fingerboard108includes a left side and a right side, with the passageway168therebetween. Support structure134extends from the support frame130along the passageway168and supports the upper rails120. In some embodiments, the fingerboard108of the upper track module112is arranged and configured to attach to and be supported by the mast106(FIG. 1). In some examples, it is cantilevered from the mast and extends over a portion of the drilling rig floor101. Other embodiments include a support structure, such as a derrick that supports the fingerboard108, and the upper rack module112.

The upper rails120are, in this exemplary embodiment, suspended from the support structure134of the fingerboard108and form an upper track for the upper cart housing122. The upper rails120are permanently fixed to the fingerboard108, and therefore are not disconnected from the fingerboard108during rig assembly, disassembly, or during transport. Accordingly, when the fingerboard108is attached to the mast106, there is little or no additional work or effort required to assemble and attach the upper rails120. The upper rails120extend along the passageway168(FIG. 2) between opposing sides of the fingerboard between the v-door172and well-center107. In the embodiment shown, the upper rails120curve or extend to a position outside the passageway168so that the upper cart housing122can travel to a position that may be used to park the racker column module114to the side of the pathway168between the v-door and well center. Accordingly, the upper rails120in this embodiment form an L-shape. Here, there are two upper rails120, however, other embodiments include additional or fewer rails, or include other structures such as the upper track.

The upper cart housing122is securely connected to the upper rails120and moves along the upper rails120via the upper cart drive124. In some embodiments, the upper cart housing122is permanently fixed to the upper rails120, and therefore is not disconnected from the upper rails120during rig assembly, disassembly, or during transport. In such embodiments, when the fingerboard108is attached to the mast106, there is little or no additional work or effort required to assemble and attach the upper cart housing to the upper rails120. In the embodiments shown, the upper cart housing122is arranged to carry the upper cart drive124and the rotational union126. In this embodiment, the upper cart housing122includes wheels and bearings enabling it to travel along the upper rails120, under the power of the upper cart drive124. Other embodiments have the upper cart drive124displaced from the upper cart housing122, and the upper cart housing122is driven by a belt, chain drive, conveyor, or other system that is powered by the upper cart drive124to move the upper cart housing122along the upper rails120. In some embodiments, the upper cart drive124is a motor arranged to move the upper cart housing122along the upper rails120.

The upper cart housing122of the upper track module112is configured to move the upper portion of the racker column module114along the upper rails120. The upper cart housing122may include rollers, sliding pads, or other structures that facilitate movement of the racker column module114between the v-door172, mousehole164, and well-center107below the mast106. In some embodiments, the upper cart housing122is a part of a chain structure that drives the racker column module114along the passageway168formed to accommodate the racker column module114through the fingerboard108.

The upper cart housing122carries the rotational union126, which engages the racker column module114. This rotational union126is configured to removeably attach to the racker column module114. A festoon system134is attached to and extends along the upper rails120and it is configured to carry one or more electrical, hydraulic, or other cables, hoses, and wires135for the operation of the upper track module112, the racker column module114, and the lower track module116. Depending on the embodiment, one, two, or all of the upper cart drive124, the rotational union126, and the festoon system134are permanently fixed to the fingerboard108, and therefore are not disconnected from the fingerboard108during rig assembly, disassembly, or during transport.

The racker column module114, shown inFIG. 4, includes a column140, a hoisting system142, a middle arm assembly144, a lower arm assembly146, a housing148, and a motor and braking system150. The racker column module114extends between and connects with the upper track module112and the lower track module116. Depending on the embodiment, one, two, three, four or all of the hoisting system142, the middle arm assembly144, the lower arm assembly146, the housing148, and the motor and braking system150are permanently fixed to the column140or a portion of the column, and therefore are not disconnected from the column140or a portion of the column during rig assembly, disassembly, or during transport.

The column140of the racker column module114provides rigidity and support to the racker system104, provides structural support of the middle and lower arm assemblies144,146, and connects the upper track module112to the lower track module116. The column140may be formed of a single solid beam or a plurality of beams joined together end to end. In some embodiments, the column140includes two parallel plates, spaced apart to hold the middle and lower arm assemblies144,146therebetween.

In this example, the hoisting system142is disposed at the top end of the column140and receives electric or hydraulic operating power from cables or hoses carried on the upper track module112. The hoisting system142may include a cable extending to the middle arm assembly144and may be used to raise and lower the middle arm assembly144along the column140.

The middle arm assembly144slides vertically along the column140and may be extended or manipulated to grasp the upper end of tubulars, carry, move or otherwise displace a tubular. In some embodiments, the middle arm assembly144may move upward or downward on rollers, slide pads, or other elements disposed on the column140or carried on the middle arm assembly. The lower arm assembly146is, in the exemplary embodiment shown, pivotably attached in place on the lower portion of the column140.

Each of the middle arm assembly144and the lower arm assembly146includes a manipulator arm152and a gripper head154. The gripper heads154may be sized and shaped to open and close and to grasp or retain tubing, such as tubulars or stands. The manipulator arms152may move the gripper heads154toward and away from the column140.

The middle arm assembly144and the lower arm assembly146are configured to reach out to insert a drill pipe stand into or remove a drill pipe stand from fingerboard108. That is, they extend outwardly from the column140to clamp onto or otherwise secure a drill pipe stand that is in the fingerboard108or to place a drill pipe stand in the fingerboard108. In addition, the middle arm assembly144and the lower arm assembly146are configured to reach out to receive tubulars introduced to the drilling rig apparatus100through the v-door172and to carry tubulars or stands from the v-door172or the fingerboard108to the mousehole164or to the well-center107for hand-off to the drilling elements, such as the top drive109. As indicated above, the middle arm assembly144may move vertically up and down along the racker column140. In some aspects, it is operated by the hoisting system142.

The housing148forms the lower portion of the column assembly114. The housing148carries the weight of the racker column140and, as is described further herein with reference toFIG. 8, interfaces with the lower track module116. The housing148can be seen best inFIGS. 4 and 8, and is arranged to provide a secure foundation for the racker column module114. With reference toFIG. 8, the housing148includes a gear driven transmission system with a projecting pinion gear155that is configured to interface with the lower track module116. The housing148also provides a powered rotational capacity to rotate the column140about its axis. Accordingly, during use, while the housing148may not rotate, the column140may be arranged to spin in order to accomplish desired tasks.

The motor and braking system150is, in the exemplary embodiments shown, carried on the housing148and is configured to rotate the projecting pinion gear155. It does this through the transmission system in the housing148and powers a lower carriage forming a part of the lower track module as is described herein. It is also configured to rotate, through the same or a separate portion of the transmission system, the column140. In this embodiment, the motor and braking system150is disposed as a part of the racker column module114. It powers the lower carriage through the interface between the racker column module114and the lower track module116. The motor and braking system150may include one or more of an electric motor, a hydraulic motor, or other motor that is arranged to turn the projecting pinion gear155and drive the lower track module116. In some embodiments, the motor is powered by the hoses or cables extending along the upper track module112, and by additional hoses or cables extending downwardly along the column140. Depending on the embodiment, these hoses or cables are respectively permanently fixed to the column140or the festoon system134, and therefore are not disconnected from the column140or the festoon system134during rig assembly, disassembly, or during transport. Accordingly, in this example, power to drive the motor and braking system150is obtained via connections made between the upper track module112and the racker column module114. It should be understood that multiple motors, types of motors, and/or pinion gears can be used. Since the motor and braking system150provides power to the lower carriage, in some embodiments, there are no separate cables or hoses connected to the lower track module116.

The lower track module116, best shown inFIGS. 4 and 6, forms and includes at least a part of the rig floor101(FIG. 1). In this exemplary embodiment, the lower track module116includes a rig floor portion with a lower track220and a lower carriage including a pair of wheel yokes222and a lower trolley224. In the exemplary embodiment shown, the lower track220is formed of a floor structure having a longitudinal gap240formed therein. The lower track220is permanently fixed to a portion of the rig floor101, and therefore is not disconnected from the portion of the rig floor101during rig assembly, disassembly, or during transport. Accordingly, when the portion of the rig floor101is installed on the rig support structure (such as a rig frame, chassis, trusses, etc.), there is little or no additional work or effort required to assemble and attach the lower track220.

The walls or sides of the gap240in the lower track220guide the direction and movement of the lower trolley224as it advances along the track220. In this example, at least one of the wheel yokes222or the lower trolley224includes a projecting element (not shown) that is arranged to extend into the gap240and maintain the direction of movement.FIG. 10shows an exemplary lower track portion with a different lower carriage disposed thereon. In this embodiment, the lower track220comprises a gear rack402along its underside that extends along the gap240and is properly spaced from the gap240to engage a gear404that extends from the lower trolley224of the lower carriage. With the gear rack402on the underside of the lower track220, the upper surface of the lower track220and also the rig floor can be maintained relatively flat. The gear rack in this embodiment is permanently fixed to the lower track, which is permanently fixed or otherwise forms a part of the rig floor. Additional details regarding the exemplary gear rack on the underside of the lower track220is shown in U.S. patent application Ser. No. 14/279,986, filed May 16, 2014, titled “Parking System for a Pipe Racker on a Drilling Rig”, expressly incorporated herein in its entirety by express reference thereto.

The wheel yokes222forming a part of the lower carriage are configured to extend over and along the gap240in the lower track220. In this embodiment, there are two wheel yokes222, with each having a protruding guide242that extends into the gap240. As the wheel yokes222advance along the lower track220, the protruding guide maintains the wheel yokes222on course. In some embodiments, the wheel yokes222extend through the gap240in the lower track220and extend under the solid lower track220in a manner that mechanically prevents removal from the lower track220. Thus, the wheel yokes222may be mechanically connected to the lower track220in a manner that allows them to be transported together without disassembly.

The lower trolley224forming a part of the lower carriage rests on and is carried by the wheel yokes222. It is configured to be disposed directly under the racker column module114and to carry the weight of the racker column module114. Accordingly, the column module114may interface with the lower trolley224and may provide power from the motor and braking system150to drive the lower trolley224along the lower track220. In this embodiment, the lower trolley224includes an extending pinion gear that engages the rack gear (not shown) disposed on the underside of the lower track220and rotates to advance the racker column module114, carried by the wheel yokes222, along the lower track220. As best seen inFIG. 6, the lower trolley224includes a support surface246and a central receiving recess248that is arranged to interface with the projecting pinion gear155(FIG. 8) of the housing148. Connectors, shown here as upwardly projecting posts250, are shaped and configured to be received in corresponding openings in the housing148to connect the lower trolley224of the lower track module116to the housing148of the racker column module114. Stabilizers252also provide structural support to prevent rotation of the lower trolley224and the housing148.

Depending on the embodiment, the wheel yokes222, the lower trolley224, or any other element of the lower carriage are permanently fixed to the lower track200, and therefore are not disconnected from the lower track during rig assembly, disassembly, or during transport.

FIGS. 7 and 8show the interfacing components of the upper track module112, the column module114, and the lower track module116. Referring first toFIG. 7, the hoisting system142at the upper end of the column140includes an engagement structure212that connects with the rotational union126. In the embodiment shown, the rotational union126may be stabbed into a receiving portion of the engagement structure212to mechanically connect the upper track module112and the racker column module114. In other embodiments, the engagement structure212or other engagement structure is stabbed into the upper carriage forming a part of the upper track module112. This physical connection permits the column140to rotate around its axis while connected to and carried by the upper cart housing122. Accordingly, when the upper cart housing122is powered to drive along the upper rails120, the top portion of the racker column module114is carried along the upper rails120also. In some embodiments, the hoisting system142is disposed elsewhere along the racker column module114and the interface between the modules occurs directly with the column140and the upper track module112. In some embodiments, the hoisting system142forms a part of the upper track module112and is used to hoist the middle arm assembly144during operation.

The interfacing connection between the upper track module112and the column module114are selectively attachable so that during operation they are fixed together, yet can be disconnected from each other so that each module may be separately removed from the drilling rig apparatus100during disassembly and then separately transported to a new location. Alternatively, they may be disassembled and replaced with a separate module in the event of repair or maintenance.

FIG. 8shows the interface between the racker column module114and the lower track module116ready to be connected together. During assembly, the projecting pinion gear155carried on the housing148is stabbed into the central receiving recess248, and the posts250are aligned with and received in the corresponding receiving holes in flanges of the housing148. The connection may be secured with additional bolts, pins, or other elements. For example, pins may be inserted through receiving holes in the posts250to prevent the racker column module from inadvertently separating from the lower carriage. In an exemplary embodiment, quick connect/release fasteners are used for rapid exchange of modules. With the projecting pinion gear155extending into the lower trolley224, a gear system in the lower trolley224can be used to drive a corresponding pinion gear (not shown) extending through the gap240of the lower track220. The corresponding pinion gear may be engaged with a gear rack on the underside of the lower track220. Accordingly, as the motor and braking system150rotates the projection pinion gear155, the projecting pinion gear155rotates a corresponding gear on the lower trolley224to advance the lower trolley224and the attached wheel yokes222along the lower track220.

FIG. 9shows an exemplary method of assembling and disassembling a modular racker system, such as the racker system104for use on the drilling rig apparatus100. The method begins at302and includes transporting the upper track module, the lower track module and the racker column module to a drill site. Since the lower track module includes the rig drillfloor with the lower track and the upper track module includes the upper racker track assembled with the fingerboard, transporting these components in an assembled state reduces transport loading and unloading time, and as set forth herein, may increase operational efficiency by reducing rig setup and teardown times.

At304, the rig floor is assembled. This may include laying out and securing the rig drillfloor sections to a structural chassis or frame forming the rig foundation of the drilling rig apparatus100. Since sections of the rig drillfloor include the lower track, and in some embodiments, the lower carriage, including the wheel yokes222and the lower trolley224, the lower track module116is installed and in position when the rig drillfloor is installed. In addition, the lower carriage may be installed when the rig drillfloor is installed.

At306, the upper track module is raised above the rig drillfloor and attached to the rig mast. This might include supporting the fingerboard via a connection to the mast so that the fingerboard cantilevers away from the mast. Since the upper track is attached to the fingerboard, the upper track is also set up and supported by the mast when the upper track module is attached to the mast. Thus, the fingerboard and the upper track are setup together at the same time.

At308, the racker column module is assembled or setup on the ground. This may include connecting components, arranging, or otherwise setting up the racker column module. Since some embodiments of the racker column module include electrical/hydraulic cables or hoses178(as shown inFIG. 4) already permanently fixed and in place on the racker column, efficiencies in assembly of the racker column module can be achieved.

At310, the racker column module114is aligned with and secured to the upper track module112. In the exemplary embodiment described herein, this includes connecting the rotational union126to a top portion of the racker column module112so that the racker column module114can rotate relative to the upper track module112. In some embodiments, this includes stabbing in the column module112to components of the upper track module112, such as the upper drive cart124, the rotational union126, or other structure forming a part of the upper carriage. Stabbing the column module112may include raising or lifting all or a portion of the racker column module112above the rig drillfloor.

At312, the lower track module116is aligned with and secured to the racker column module114. This may include stabbing a portion of one of the racker column module and the lower track module into the other so that they are mechanically connected and securely attached to one another. In some examples, this includes aligning the lower carriage under the racker column module114while the racker column module114is raised and stabbed into the upper carriage. Accordingly, with the racker column module114above the drill rig floor, the lower carriage is aligned along the lower track to be under the racker column module, and the racker column module is lowered onto the lower carriage. In embodiments described herein, lowering the racker column module onto the lower carriage includes stabbing the projection pinion gear155into a central receiving recess248in the lower trolley224so that power from the racker column module may be transmitted to the lower track module.

At314, electrical or hydraulic connections are made to connect the upper track module to the racker column module. Since in the exemplary embodiment described, the hoses or cables already form a part of the upper track module and the racker column module, there is no need to run the hoses and cables during the assembly process. In some embodiments, the hoses and cables provide electric or hydraulic power to the motor and braking system150, the housing148, and the middle and lower arm assemblies144,146on the racker column module114. With this arrangement, connections need only be made at one location to connect (or to disconnect) to the upper and lower track modules. In some embodiments, it also provides electrical or hydraulic power to the lower track module through the racker column module. In embodiments where the lower track module requires electrical or hydraulic connection, those connections may also be made to connect hoses or cables that make up a portion of the respective modules.

At316, the assembled racker system104is used to perform a drilling rig operation, such as manipulate tubulars, makeup or breakdown stands, or perform other functions.

When desired, the racker system104may be disassembled for transportation to a new drill site. This process is in many respects simply the reverse of the setup process, and not all steps or elements are repeated in the same level of detail as above. Disassembly however may begin at318by disconnecting the electrical or hydraulic connections on the upper track module from the connections on the racker column module.

At320, the racker column module is disconnected from the lower track module by raising the racker column module to separate it from the lower carriage, and the lower carriage or the racker column module may be moved so that the carriage is not under the racker column module. At322, the racker column module is disconnected from the upper track module. This may include lowering the racker column module so that the interfering structure that was stabbed into the upper column module is removed from the upper column module. At324, the racker column module is disassembled for transport. At326, the upper track module is removed from the mast by removing the fingerboard and lowering it to the ground and preparing it, with the lower track and other upper track module components, for transport. At328, the drill rig floor is disassembled into sections, with the lower track forming a part of at least one of the drillfloor sections. At3320, the modules are transported to a second drill site for reassembly onto a drilling rig. Since the modules are transported in an assembled or a partially assembled state including with attached electrical cables and/or hydraulic hoses, the assembly and disassembly of the drilling rig apparatus may be expedited, resulting in more efficient, and therefore less expensive, rig operations.

While the modules described herein have certain components associated therewith, it should be understand that the modules may be arranged so that different components form a part of different modules. For example and without limitation, the motor and braking system150carried on the racker column module may alternatively be carried on the lower track module. Other components may be likewise redistributed depending on the racker device arrangement. In addition, not all modules have all the components identified in the exemplary racker disclosed herein. For example, some rackers may have fewer arm assemblies than what are disclosed here. Likewise, because of its length, some embodiments of the racker column module114may be broken down further, for example, with a first module including a column portion and the middle arm assembly and a second module including a column portion and the lower arm portion, with the arm portions still attached to and forming a part of the column during assembly, disassembly, or transport.

In view of all of the above and the figures, one of ordinary skill in the art will readily recognize that the present disclosure introduces a drilling rig apparatus that includes a transportable lower track module comprising a drilling rig floor comprising a lower track arranged and configured to accommodate a lower carriage. The lower track may be permanently fixed to the drilling rig floor so as to form a part of the drilling rig floor and being transportable as part of the drilling rig floor. A racker column is operably attachable to the lower carriage track module. A transportable upper track module includes a fingerboard and an upper track arranged and configured to accommodate an upper carriage moveable along the upper track. The upper track is permanently fixed to the fingerboard and is transportable in a connected configuration. The upper track module is operably attachable to the racker column.

In an aspect, the racker column forms a part of a racker column module that also comprises an arm assembly permanently fixed to the racker column and a hoisting system arranged to raise and lower the arm assembly along the racker column. In an aspect, the lower track module comprises a lower carriage attached to and moveable along the lower track, the lower carriage comprising a portion extending through the lower track in a manner that retains the lower carriage in place on the lower track during transportation. In an aspect, the upper track of the upper track module and the lower track of the lower track module each have a portion forming an L-shape. In an aspect, the upper track module comprises an upper carriage permanently fixed to and moveable along the upper track, the upper carriage being connected to the upper track in a manner that retains the upper carriage in place on the lower track during transportation. In an aspect, the racker column forms a part of a racker column module comprising a motor and braking system arranged to power the lower carriage of the lower track module when operably connected thereto. In an aspect, the lower track module includes the lower carriage permanently fixed to the lower track. The lower carriage includes a support surface configured to support the racker column, and one of a projecting gear and a receiving recess. The racker column forms a part of a racker column module including the other of the projecting gear and the receiving recess. The projecting gear is arranged to fit within the receiving recess connecting the rack column module and the lower carriage.

In another aspect, the present disclosure introduces a drilling rig apparatus that includes a transportable lower track module comprising a portion of a drilling rig floor comprising a lower track arranged and configured to accommodate a lower carriage. The lower track is permanently fixed to a part of the drilling rig floor and is transportable as a part of the drilling rig floor. A transportable racker column module is selectively attachable to the lower carriage track module. The racker column module comprises a racker column and an arm assembly permanently fixed to the column and arranged to manipulate a tubular. A transportable upper track module includes a fingerboard and an upper track arranged and configured to accommodate an upper carriage moveable along the upper track. The upper track module is permanently fixed to the fingerboard and comprises a connector element configured to couple with the racker column module.

In an aspect, the lower track module comprises a lower carriage permanently fixed to and moveable along the lower track, the lower carriage comprising a portion extending through the lower track in a manner that retains the lower carriage in place on the lower track during transportation. In an aspect, the upper track of the upper track module and the lower track of the lower track module each have a portion forming an L-shape. In an aspect, the upper track module comprises an upper carriage permanently fixed to and moveable along the upper track, the upper carriage being connected to the upper track in a manner that retains the upper carriage in place on the lower track during transportation. In an aspect, the racker column module comprises a hoisting system permanently fixed to the column and a second arm assembly moveable with the hoisting system. In an aspect, the racker column module comprises a motor and braking system permanently fixed to the column and arranged to power the lower carriage of the lower track module when operably connected thereto.

In another aspect, the present disclosure introduces a method of modifying a rig which comprises: installing a lower track module on a drilling rig apparatus, the lower track module comprising a lower track permanently fixed to a drilling rig floor, the lower track arranged and configured to accommodate a lower carriage; connecting a racker column to the lower track module in a manner that a lower carriage transports the racker column along the lower track; and connecting an upper track module to the racker column, the upper track module comprising a fingerboard permanently fixed to upper track that is arranged and configured to accommodate an upper carriage moveable along the upper track in a manner that an upper carriage of the upper track module transports the racker column along an upper track of the upper track module.

In an aspect, connecting the racker column to the lower track module comprises connecting a racker column module that includes extendable arms for grasping a tubular to the lower track module. In an aspect, the method includes connecting one or more electrical cables or hydraulic hoses of the racker column to an electrical cable or hydraulic hose of the upper track module. In an aspect, the racker column forms a part of a racker column module, and wherein connecting an upper track module to the racker column comprises stabbing a component carried by one of the upper track module and the racker column module into the other of the upper track module and the racker column module. In an aspect, the racker column forms a part of a racker column module, and wherein connecting the racker column to the lower track module comprises stabbing a component carried by one of the racker column module and the lower track module into the other of the racker column module and the lower track module. In an aspect, the method includes disconnecting the upper track module from the racker column; disconnecting the lower track module from the racker column; and transporting the lower track module and the upper track module to a new location with the lower carriage connected to the lower track and with the upper carriage connected to the upper track. In an aspect, the racker column forms a portion of a racker column module, and the method further comprises driving the lower carriage along the track with a motor forming a part of the racker column module.

Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.