Pinned structural connection using a pin and plug arrangement

Generally, the subject matter disclosed herein is directed to, among other things, systems and methods for making up pivotably pinned structural connections that may be used for erecting drilling rig masts. One illustrative system includes a drilling rig mast having at least one support leg, a drilling rig mast support having at least one mast support shoe, and a pinned connection between the at least one support leg and the at least one mast support shoe. Additionally, the pinned connection of the disclosed system includes a pin, an oversized hole having at least a first hole portion, and a removable plug that is adapted to be inserted into the oversized hole, wherein the removable plug has at least a first plug surface portion, and wherein the first hole portion and the first plug surface portion define at least part of a pin hole that is adapted to receive the pin.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Generally, the present disclosure relates to devices and methods for making up pivotably pinned structural connections, including, among other things, the pinned structural connections that may be used to facilitate the erection of drilling rig masts.

2. Description of the Related Art

The prior art discloses a variety of rigs used in drilling and wellbore operations and methods of rig assembly; for example, and not by way of limitation, rigs and assembly methods as disclosed in U.S. Pat. Nos. 2,857,993; 3,340,938; 3,807,109; 3,922,825; 3,942,593; 4,021,978; 4,269,395; 4,290,495; 4,368,602; 4,489,526; 4,569,168; 4,821,816; 4,831,795; 4,837,992; 6,634,436; 6,523,319; 6,994,171; 7,306,055; 7,155,873; and 7,308,953 and the references cited in these patents—all these patents incorporated fully herein for all purposes.

In many drilling operations, drilling rigs and related systems, equipment, and apparatuses are delivered to a site, assembled and then disassembled. It is important that drilling rigs and their components be easily transported and assembled. Costs associated with land rigs and associated equipment, can be calculated on a per hour or per day basis, and, therefore, efficient assembly, takedown, transport, and setup operations are desirable.

U.S. Pat. No. 3,922,825 discloses a rig with a stationary substructure base and a movable substructure base mounted thereon which is coupled to the stationary base and swings upright into an elevated position on a series of struts that are connected to the stationary base with swivel connections at each end. The movable base is otherwise stationary since neither the stationary base nor the movable base are mobile or repositionable without the use of an auxiliary crane or the like. The movable substructure base and the drill mast are raised with a winch mounted on an auxiliary winch truck.

U.S. Pat. No. 3,942,593 discloses a mobile well drilling rig apparatus which has a trailerable telescoping mast and a separate sectionable substructure assembly with a rig base, a working floor, and a rail structure. The mast is conveyed to the top of the substructure by rollers and is raised by hydraulic raising apparatus to an upright position. With such a system, the mast assembly can be relatively long when transporting it and the mast can be unstable during raising. This system uses drawlines and winch apparatus to raise the mast onto the working floor.

U.S. Pat. No. 4,021,978 discloses a telescoping mast assembly adapted for use with drill rigs and the like. The mast assembly has multiple sections, said sections being adapted for nesting one within the other in the telescoped-to-the-closed condition and each section has mutually convergent corner leg members which, when the mast assembly is extended, form concentric and in-line arrangements of the corner leg members from the base to the crown of the mast. Means are provided for connecting each mast section to its neighboring mast section upon extension thereof. In addition, means are also provided for indexing of the connector means upon extension of the mast assembly from its telescoped-to-the-closed condition.

U.S. Pat. No. 4,821,816 discloses methods of assembling a modular drilling machine which includes a drilling substructure skid which defines two spaced parallel skid runners and a platform. The platform supports a draw works mounted on a draw works skid, and a pipe boom is mounted on a pipe boom skid sized to fit between the skid runners of the drilling substructure skid. The drilling substructure skid supports four legs which in turn support a drilling platform on which is mounted a lower mast section. The legs are pivotably mounted both at the platform and at the drilling substructure skid and a pair of platform cylinders are provided to raise and lower the drilling platform. A pair of rigid, fixed length struts extend diagonally between the platform and the substructure skid away from the platform such that the struts do not extend under the platform and obstruct access to the region under the platform. The pipe boom skid mounts a pipe boom as well as a boom linkage, a motor, and a hydraulic pump adapted to power the pipe boom linkage. The substructure skid is formed in upper and lower skid portions, and leveling rams are provided to level the upper skid portion with respect to the lower skid portion. Mechanical position locks hold the upper skid in relative position over the lower skid. In one aspect such a method for assembling an earth drilling machine includes the steps of: (a) providing a modular earth drilling machine comprising a drilling substructure skid, a draw works skid, and a pipe boom skid, the drilling structure skid having a collapsible drilling substructure platform and means for receiving the draw works skid and the pipe boom skid, the draw works skid having a draw works winch, and the pipe boom skid having a pipe boom pivotably mounted to the pipe boom skid for rotation about a pivot axis, at least one hydraulic cylinder coupled between the pipe boom and the pipe boom skid to rotate the pipe boom about the pivot axis, a hydraulic pump mounted to the pipe boom skid and coupled to the hydraulic cylinder by a closed hydraulic fluid circuit, and a pipe boom skid winch; the pipe boom skid, pipe boom, hydraulic cylinder and hydraulic pump forming a modular unit which is transportable as a single unit without any disconnection of the closed hydraulic fluid circuit; (b) positioning the substructure skid at a desired drilling position; (c) utilizing the pipe boom skid winch to pull the pipe boom skid into position with respect to the substructure skid; (d) utilizing the pipe boom skid winch to pull the draw works skid into position with respect to the substructure skid; and, in one aspect, the method further including raising the collapsible drilling structure platform, including utilizing the pipe boom skid winch to lift the drilling structure platform during at least an initial stage of the raising step.

U.S. Pat. No. 4,831,795 discloses drilling derrick assemblies which provide for the elevation above ground level of the assembly's working floor which supports both the mast and the drawworks. Prior to erection, the elevatable equipment floor is carried on a supporting substructure, and a mast is pivotally connected to the elevatable floor in a reclining position. When the assembly is erected, the mast is pivotally raised and attached in place, and other rigging steps can be carried out. Through the use of an integrally mounted sling and winch assembly or, alternatively, through operation of the assembly's traveling block, the entire equipment floor is elevated to the desired level. In one aspect, a drilling structure is disclosed that has: a substructure for supporting the drilling structure on the surface through which drilling is to occur, an elevatable floor assembly which rests on the substructure in its lowered position, a reclining mast pivotally connected to the elevatable floor, a gin pole assembly mounted on the elevatable floor assembly rearwardly of the point at which the mast is pivotally connected to the elevatable floor and arranged to receive line for raising the mast, whereby the mast is raised prior to raising the elevatable floor assembly, a collapsible vertically standing elevating frame assembly mounted on the substructure and forwardly of the mast, when raised, and the forwardmost end of the elevatable floor assembly, winch means rotatably mounted in and arranged adjacent the forwardmost end of the substructure, a first elevating block means mounted in the elevatable floor and rearwardly of the elevating frame assembly, a second elevating block mounted on the elevating frame assembly at a vertical point corresponding with the level to which the elevatable floor is to be raised, an elevating line extending from the winch means and reeved about the elevating block so that motion of the winch means in one direction causes the second elevating block to move toward the first elevating block raising the elevatable floor vertically and forwardly, motion of the winch means in another direction lowering the elevatable floor vertically and rearwardly, and a brace member on each side of the drilling structure, each brace member being pivotally connected at its ends, respectively, to the substructure and the elevatable floor, the brace members being arranged in pairs forming parallel linkages thereby causing the elevatable floor assembly to be raised in an arc-like motion.

U.S. Pat. No. 6,994,171 discloses two section masts with self-aligning connections and methods with self-aligning connections for a two section mast. The methods include the steps of transporting the elongated bottom mast section to a guide frame adjacent to a well site, the bottom mast section having a pair of front legs and a pair of rear legs. An elongated top mast section is transported to the well site, the top mast section having a pair of front legs and a pair of rear legs. The legs of the bottom mast section are positioned slightly below a level of the legs of the top mast section. Thereafter, the bottom mast section is raised slightly to order to engage the top mast section while simultaneously aligning the mast sections together. The sections are thereafter pinned together. In one method of self-aligning connections for a two section mast, the method includes: transporting an elongated bottom mast section to a guide frame adjacent to a well site, the bottom mast section having a pair of front legs and a pair of rear legs so that the bottom mast section is in a substantially horizontal orientation; thereafter transporting an elongated top mast section to the well site so that the top mast section is in a substantially horizontal orientation and so that the mast sections are substantially aligned lengthwise, the top mast section having a pair of front legs and a pair of rear legs; positioning the legs of the bottom mast section slightly below a level of the legs of the top mast section; raising the bottom mast section; and simultaneously engaging and guiding the mast sections together in a final connecting orientation.

U.S. Pat. No. 7,155,873 discloses structural connectors for a drilling rig substructure; and a method and apparatus for connecting sections of a drilling rig substructure, in one aspect a structural connector is provided so that sections of a drilling rig substructure can be connected together without the use of pins or pin-type connectors. The structural connector utilizes specially-shaped fixed members connected to, and extending through, support plates that are attached to sections of a drilling rig substructure that mate with specially-shaped mating lugs that are mounted on mating lug plates that are attached to separate sections of the drilling rig substructure. When the sections of the drilling rig substructure to be connected are positioned together, the specially-shaped mating lugs engage the specially-shaped fixed members and form a high strength structural connection between the sections of the drilling rig substructure. In one aspect a structural connector is provided that has: a plurality of support plates each having a plurality of fixed support members extending therethrough, the fixed support members extending outwardly from both sides of the support plates and having side walls and contoured tops; a mating lug assembly having a plurality of mating lug plates and a plurality of mating lugs attached to each mating lug plate, each mating lug having a support notch therein; wherein the support notch of each mating lug has tapered guide surfaces at the entry point of the support notch, side walls, and a contoured top.

SUMMARY OF THE INVENTION

The following presents a simplified summary of the present disclosure in order to provide a basic understanding of some aspects disclosed herein. This summary is not an exhaustive overview of the disclosure, nor is it intended to identify key or critical elements of the subject matter disclosed here. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.

The present invention, in certain aspects, provides drilling rigs with erectable masts. In one aspect, a mast includes a bottom mast component and a second, upper or midsection component that are connected together.

In certain aspects, the present invention discloses a bottom mast section connectible to a midsection by moving a vehicle, e.g. a truck/trailer combination to place the two sections adjacent each other; connecting the bottom section to a support, e.g. but not limited to, a rig's substructure; raising, if necessary, the support or rig's substructure to which the bottom mast section is connected; and moving the vehicle to engage connections and, in one aspect, to align connections, of the bottom mast section and midsection. Once the connections have been engaged, the truck can move away and pins are used as a further securement to lock the two sections together and the truck moves away.

The present invention discloses, in certain aspects, a method for connection two parts of a mast of a drilling rig, the method including: connecting a bottom mast section to a support, the bottom mast section having bottom connection apparatus; moving a second mast section adjacent the bottom mast section, the second mast section releasably connected to a vehicle and said moving done by moving said vehicle, the second mast section having second connection apparatus; and moving the bottom mast section so that the bottom connection apparatus contacts the second connection apparatus and engages the second connection apparatus to secure the bottom mast section to the second mast section, and, in certain aspects to facilitate connection engagement and align the mast sections as one mast section is lifted.

The present invention discloses, in certain aspects, a mast system for rig operations, the mast system including: a support, a bottom mast section connected to the support; the bottom mast section having bottom connection apparatus; a second mast section adjacent and connectible to the bottom mast section, the second mast section releasably connected to a vehicle for moving the second mast section; the second mast section having second connection apparatus; and the bottom mast section movable on the support so that the bottom connection apparatus can contact the second connection apparatus and engage the second connection apparatus to secure the bottom mast section to the second mast section.

One illustrative system of the present disclosure includes, among other things, a drilling rig mast having at least one support leg, a drilling rig mast support having at least one mast support shoe, and a pinned connection between the at least one support leg and the at least one mast support shoe. Additionally, the pinned connection of the disclosed system includes a pin, an oversized hole having at least a first hole portion, and a removable plug that is adapted to be inserted into the oversized hole, wherein the removable plug has at least a first plug surface portion, and wherein the first hole portion and the first plug surface portion define at least part of a pin hole that is adapted to receive the pin.

Another illustrative system disclosed herein includes a drilling rig mast having at least one mast section, wherein the at least one mast section comprises at least one support leg, and the at least one support leg comprises a first pin hole having a substantially circular shape. The system further includes a drilling rig mast support comprising at least one mast support shoe, wherein the at least one mast support shoe comprises an oversized hole, and the oversized hole is made up of at least a first hole portion having a substantially circular shape. Additionally, the system includes, among other things, a pin that is adapted to pivotably attach the at least one support leg to the at least one support shoe, wherein the pin has a substantially circular cross section and is adapted to be inserted into the first pin hole and the oversized hole, and wherein the pin and is further adapted to be positioned adjacent to the first hole portion. Furthermore, the system also includes a removable plug that is adapted to be inserted into the oversized hole and is further adapted to maintain the position of the pin adjacent to the first hole portion, wherein the removable plug comprises at least a first plug surface portion that is adapted to be positioned adjacent to the pin, wherein the first hole portion and the first plug surface portion define at least part of a second pin hole having a substantially circular shape, and wherein the second pin hole is adapted to receive the pin.

Also disclosed herein is an illustrative method that includes, among other things, positioning a support leg of at least one mast section of a drilling rig mast proximate a mast support shoe of a drilling rig support, and aligning a first substantially circular pin hole of the support leg with an oversized hole of the mast support shoe, wherein the oversized hole is made up of at least a first hole portion having a substantially circular shape. The method also includes pivotably attaching the support leg to the mast support shoe by inserting a pin having a substantially circular cross section into the aligned holes, positioning the pin adjacent to the first hole portion, and inserting a removable plug into the oversized hole so as to substantially maintain the position of the pin adjacent to the first hole portion, wherein the removable plug has at least a first plug surface portion, and wherein the first hole portion and the first plug surface portion define a second substantially circular pin hole that is adapted to receive the pin.

DETAILED DESCRIPTION

FIG. 1Ashows a drilling rig's substructure11supporting a drill floor12with a drawworks14positioned on the drill floor12. The substructure11and drill floor12have an open area A into which equipment can be moved.

As shown inFIG. 1Cthe substructure11is in a lower position and a truck T has moved a bottom section20of a mast according to the present invention toward the drill floor12. An A-frame13is connected to the bottom section20of the mast. Mast raising cylinders22are in position for connection to the bottom section20.

As shown inFIG. 1D, the truck T is stopped moving the bottom section20into the area A. The bottom section20is then connected to the mast raising cylinders22. The positions substructure raising cylinders18are adjusted and the A-frame13is connected to the drill floor12.

As shown inFIG. 1E, legs21of the mast20are swung open for bolting to mast shoes23of the drill floor12. The mast raising cylinders22are then extended and the truck T is moved away. The mast raising cylinders22are then retracted to lower the bottom section20.

As shown inFIG. 1F, a truck R has moved a midsection30of a mast according to the present invention toward the bottom section20.FIG. 1Gshows the truck R stopped after moving the midsection30adjacent a projecting end of the bottom section20. The sub cylinder18and the mast cylinder22are raised to raise jaw members according to the present invention of the bottom section20adjacent corresponding connection members32according to the present invention of the midsection30.

FIGS. 1I-1Lshow the bottom section20andFIGS. 1M-1Pshow the midsection30. The bottom section20has two legs20aeach with a jaw member29having a slot23in each of two spaced-apart plates24. A space25is formed between ends of the plates24. A throat25ais formed between flared out portions25bof the plates24(or separate pieces25bare used connected to the plates). Two legs20reach have a connection member26with two spaced-apart plates27and holes28. A throat27ais formed between flared out portions27bof the plates27. A throat27cis formed between flared out portions27dof the plates27. In certain aspects of the present invention, any one or two throats described above may be deleted, or they may all be deleted.

As shown inFIGS. 1F-1L, the midsection30has two legs31each with a connection member32having a transverse bar33. Each leg has a connection member35with holes38corresponding, upon section connection, to the location of the holes28of the connection members26.

Ends of the connection members32are sized for movement into the spaces25of the jaw members29and the bars33are sized for receipt in the slots23. The connection members35are sized for receipt between the plates27of the connection members26and pins are insertable through the holes28,38to lock the two mast sections together. If one jaw member connects to one connection member and the other jaw-member/connection/member connection has not been fully effected, raising of the bottom section will force the other connection member into contact with and engagement with the other jaw member, facilitating alignment of the two sections and their connection.

The truck R moves the midsection30adjacent the bottom section20so that ends of the connection members32move into the spaces25of the jaw member29and the bars33then move into the slots23. The connection members35are moved through the throats27abetween the plates27and pins are inserted through the holes28,38to lock the two sections together.

It is within the scope of this invention to delete one of the jaw members29and to releasably connect the two sections of the mast together at the location of the deleted jaw member29in any suitable fashion (e.g., but not limited to) with bolt(s) bolting the two sections together.

Upon interengagement of the connection members of the sections20,30, as shown inFIG. 1H, and insertion of locking pins through the holes28,38, the mast raising cylinders22are partially extended so the truck R can move away. The mast raising cylinders22are then further extended and a racking board B is opened.

FIG. 2shows a bottom section120of a mast according to the present invention (like the bottom section20); andFIG. 3shows a midsection130of a mast according to the present invention (like a midsection30).

As shown inFIG. 2, the bottom section120has four legs122and a series of interconnecting beams121. A square tube123spans two of the legs122. Each of two of the legs122has a jaw member126like the jaw members29,FIG. 1Fand the two opposite legs122have end connection members127(like the connection members27,FIG. 1F).

A jaw member126has a body126awhich includes two spaced-apart plates126psecured to a leg122; a slot126b; an upright projection126c; and a throat126d(like the throat25a,FIG. 1L) between two flared out parts which decreases in width from an outer end to an inner end.

An end connection member127has a body127awith two spaced-apart plates127peach with a flared end127eso that the plates127ptogether form an open throat127twhich decreases in width from the outer end to the inner end. Each plate127phas a hole127hfor receiving a removable locking pin. A throat127xis formed between parts127y. The throat127tis like the throat27c,FIG. 1Land the throat127xis like the throat27a,FIG. 1L.

As shown inFIG. 3, the midsection30has four legs132and a series of interconnecting beams131. Each of two of the legs132has a connection member136and the two opposite legs have a connection member137.

Each connection member136has a body136amade of two plates136p. A bar136bis held by and projects slightly from the plates136p.

Each connection member137has a body137amade of two plates137p. Each plate137phas a hole137hfor receiving a removable locking pin.

As shown inFIGS. 4A-4Cthe midsection130has been moved on a truck into position adjacent the bottom section120(e.g. as inFIG. 1Fand prior toFIG. 1G). The truck moves the midsection130directly above the bottom section120(FIG. 4C). A substructure (e.g. like the substructure11) raises the bottom section. For mating of the upper mast section initially to the lower mast section, both sections are oriented so that they are sloping downwards towards each other to insure that the upper jaws126come to a mating position before the opposite connections. The jaws126are then brought into contact with the mating bars136bof the lower connection members by raising the lower mast section using the hydraulic cylinders.

Continued raising then forces the mating ends of the mast sections upwards rotating them so that the gap between the lower connections is forced closed. The flared design on the lower connections forces them into alignment as they are forced closed. As shown inFIGS. 4F and 4G, the hydraulic cylinders (substructure raising cylinders and mast raising cylinders) have been raised to raise the bottom section120level with the midsection130, moving the connection member137fully into the connection member127. Pins129have not yet been inserted into and through the holes127h,137h. The bars136bare in the slots126s. The two sides of the mast can be misaligned when the connection method starts which can result in a jaw and bar on one side being tensioned while the opposite jaw and bar are floating—but this is self-corrected as the raising process continues and the total mast begins to be lifted.

As shown inFIGS. 4G and 4H, the substructure raising cylinders and the mast raising cylinders have been adjusted to install the pins129have been inserted through the connection member127,137. Pins139have not yet been inserted into the slots126b. Each pin139has a body139awith a lower projection139cwhich is sized and configured to fit into a space131formed by surfaces of the connection member126and of the bars136b.

Once the pins139have been inserted and the two mast sections120,130are connected, the mast is ready to be raised.

In some embodiments of the present invention, the support legs of the drilling rig mast may be attached to the mast support shoes by means of removable cylindrically shaped pins, rather than being bolted to the shoes as described with respect toFIG. 1Eabove. In such embodiments, the support legs of the drilling rig mast may be attached to the mast support shoes on the drilling rig floor or substructure by aligning pin holes in the “feet”, or lower ends, of the support legs with pin holes in the mast support shoes. Thereafter, the removable pins may be installed by sliding, or driving, the pins into place. However, in typical configurations, the clearances between each of the pin holes and the removable pins may be quite small, which, depending on the overall rig structure design, may be necessary so as to properly transfer the loads on and from the drilling rig mast to the mast support shoes and the rig substructure, while still permitting the drilling rig mast to be pivoted about the pins during rig erection. As such, the feet of each support leg may need to be very closely aligned with the shoes before the removable pins can be installed. Furthermore, there is often a desire to install the drilling rig mast from the trailer of the truck that is used to transport the mast to the drilling site, directly to the mast support shoes. In some instances, this activity can create additional difficulties in ensuring that the truck/trailer is properly located and positioned during the pin hole alignment process, which may be a time consuming and laborious step in the overall erection of the drilling rig mast. Accordingly, this method of direct drilling rig mast installation is oftentimes abandoned, resulting in the reversion to more traditional, and significantly more costly, erection methods, such as the use of a large crane to lift and manipulate the mast.

FIGS. 5A-5Fillustrate a drilling rig system and method for erecting a drilling rig mast using a novel pinned structural connection of the present disclosure, which will hereinafter be described in detail.

As shown inFIG. 5A, a bottom section520of a drilling rig mast may be positioned on a trailer502of a truck/trailer combination500in preparation for moving the bottom section520to a drilling rig substructure511, which, in some illustrative embodiments, may be substantially similar to the substructure11depicted inFIGS. 1A-1Hand described above. In some embodiments, the bottom section520may include support legs521, and the support legs521may have pin holes541located at the lower end thereof, and which may be used to pivotably attach the bottom section520to the drilling rig substructure511, as will be described in detail below. The bottom section520may also include support struts524, which may be pivotably attached to the bottom section520by pinned connections540. Furthermore, as with the support legs521, the support struts524may also have pin holes544located at a lower end thereof, and which may be used to attach the support struts524to the drilling rig substructure511.

In certain embodiments of the present disclosure, the drilling rig substructure511may include a drilling floor512and a plurality of substructure raising apparatuses518, such as hydraulic cylinders and the like, that may be pivotably attached to substructure511and drilling rig floor512. In some illustrative embodiments, the drilling rig substructure511may include mast support shoes523to which the support legs521may be pivotably attached. The mast support shoes523may be located on the drilling floor512, and may each have pin holes543corresponding to the respective pin holes541at the lower ends of the support legs521. In other illustrative embodiments, the drill rig substructure511may also include strut support shoes525to which the support struts524may be attached after erection of the drilling rig mast. Similar to the mast support shoes523, the strut support shoes525may also be located on the drilling floor512and may include pin holes545corresponding to the respective pin holes544at the lower ends of the support struts524. In yet other illustrative embodiments, the drilling rig substructure511may also include a mast raising apparatus522, such as one or more hydraulic cylinders and the like, that may be used to erect the drilling rig mast after the support legs521have been pivotably attached to the mast support shoes523, which will be described in detail below.

In some illustrative embodiments disclosed herein, the pin holes541of the support legs521may have a substantially circular shape, as may typically be used for a pinned structural connection that is designed to transfer a load from one structural component to another, while simultaneously allowing one of the members to be rotated freely about the pin that used to connect the two components. Accordingly, the pin holes541may be substantially the same shape and size as the removable pin546(see,FIGS. 5C-5F) that is used to attach the support legs521to the mast support shoes523, giving due consideration to the clearances and tolerances that may be necessary for the requisite load transfer and joint rotation described above. On the other hand, the pin holes543of the mast support shoes523may be oversized—i.e., larger than the pin holes541—so as to address the pin hole alignment and pin fit-up issues previously described. The pin holes543may be substantially any size and shape, provided, however, they are larger than the pin holes541, and are of such a size as to facilitate any anticipated alignment issues that might arise during the positioning of the bottom section520. For example, in certain illustrative embodiments, the pin holes543may have a substantially non-circular shape, such as teardrop shape and the like, as shown inFIG. 5A, and as is also illustrated in further detail inFIGS. 6A-6Eand described below. Accordingly, the substantially circular pin holes541may be more easily aligned with the oversized pin holes543prior to installation of the pin546.

As shown inFIG. 5A, a truck501of the truck/trailer combination500may position the trailer502in an open area of the drilling rig substructure511and drilling floor512, such as the open area A illustrated inFIG. 1Band described above. In certain embodiments, the bottom section520of the drilling rig mast may be moved rearwardly and inside of the open area (see, open area A ofFIG. 1B) of the drilling floor512on rollers548, so that the lower ends of the support legs521may be positioned proximate the mast support shoes523. Thereafter, the lower end of the bottom section520may be raised by a movable raising device (not shown), such as a rolling hydraulic jack and the like, and the position of the bottom section520may be adjusted relative to the drilling floor512until the pin holes541of the support legs521are substantially aligned with oversized pin holes543of the mast support shoes523, as shown inFIG. 5B. After the pin holes543and541are substantially aligned, a removable pin546having a substantially circular cross section may then be inserted into the aligned pin holes, as shown inFIG. 5C. In some illustrative embodiments, the removable pin546may have substantially the same size and shape as the pin holes541, considering, of course, the clearances and tolerances that may be required to obtain a rotatably pinned structural connection, as described above. Furthermore, in this configuration the removable pin546may be substantially supported by the substantially circular pin holes541of the support legs521, and may not yet be in contact with any of the surfaces of the oversized pin holes543of the mast shoe supports523.

FIG. 5Dillustrates the drilling rig system ofFIGS. 5A-5Cin a further advanced assembly stage. As shown inFIG. 5D, in some illustrative embodiments, the mast raising apparatus522, such as a hydraulic cylinder and the like, may be pivotably attached to an erection lug549on the bottom section520of the drilling rig mast. Thereafter, the mast raising apparatus522may be extended so as to move the bottom section520relative to the drilling rig substructure511. Accordingly, the support legs521and the pin546inserted into the pin holes541thereof will also be moved relative to the mast support shoes523until at least a first pin surface portion546S of the pin546is adjacent to, or even in contact with, at least a first hole portion543S of the oversized pin holes543. Preferably, the size and shape of the first hole portion543S that is adjacent to and/or in contact with the pin546is adapted to rotatably cooperate with the first pin surface portion546S. In this way, when the pinned connection550(see,FIGS. 5E-5F) has been fully assembled as described below, the removable pin546may be able to transfer loads between the support leg521and the mast support shoe523, as well as facilitate the pivotable rotation of the support leg521during the erection of the drilling rig mast, as previously described.

For example, in some embodiments of the illustrative oversized pin hole543having a teardrop-like shape as shown inFIGS. 5A-5F, the pin546may be moved adjacent to and/or in contact with the first hole portion543S at the smaller end543E of the teardrop shaped pin hole543. Furthermore, the first hole portion543S may have a substantially circular shape that is substantially the same size and shape as the first pin surface portion546S of the pin546that is adjacent thereto. Moreover, in certain illustrative embodiments, the first hole portion543S of the oversized pin hole543may be provided with similar clearances and tolerances with respect to the removable pin546as may be used for the substantially circular pin holes541, thereby enabling the requisite load transfer and pivotable rotation previously described.

Additionally, in some illustrative embodiments, the mast raising apparatus522may also lift, or take the dead load of, the upper end of the bottom section520of the drilling rig mast such that the rollers548are no supported by trailer502of the truck/trailer combination500. Thereafter, the truck501may move the trailer502from the open area (see, e.g., open area A ofFIG. 1B) of the drilling rig substructure511and the drilling floor512, thereby facilitating further drilling rig mast erection activities.

FIG. 5Eillustrates the drilling rig system ofFIGS. 5A-5Din yet a further advanced assembly stage. As shown inFIG. 5E, after the mast raising apparatus522has been actuated and the first pin surface portion546S of the pin546has been moved adjacent to and/or into contact with the first hole portion543S at the small end543E of the oversized pin holes543, a removable plug547may be inserted into the pin holes543proximate the pin546so as to maintain the pin546in this position. In certain illustrative embodiments of the present disclosure, the removable plug547may be shaped so that a first plug surface portion547S of the plug547has a substantially circular shape that may be substantially the same size and shape as a second pin surface portion546X of the pin546that is immediately adjacent thereto. Furthermore, in some embodiments, a combined shape that is defined by the first hole portion543S (shown as a dotted line inFIG. 5E) of the oversized pin hole543and the first plug surface portion547S of the removable plug547may define a substantially circularly shaped pin hole opening246P, wherein the pin546will be “captured”, or maintained in place, after the plug547has been inserted into the hole543. Moreover, in certain embodiments, the pin hole opening246P may be substantially the same size and shape as the substantially circular pin holes541of the support legs521, as will be described in further detail with respect toFIGS. 6A-6Ebelow.

In certain illustrative embodiments, the removable plug547may be made up of two or more separate plug parts, such as plug parts547A and547B (as indicated by a dotted line inFIG. 5E), which may facilitate easier plug installation and/or removal. Furthermore, in at least some embodiments, the removable plug547may be shaped so as to fittingly—i.e., non-rotatably—engage a second hole portion543X of the oversized pin holes543(see,FIG. 5D). Moreover, the removable plug547may be sized and shaped so as to substantially fill a remaining portion of the oversized pin holes543, as shown inFIG. 5E. For example, the removable plug547may have a second plug surface portion547X that may be in substantially continuous contact with the second hole portion543X. In this way, the fully assembled pinned connection550—which includes both the removable pin546and the removable plug547—may be capable of transferring loads from, and facilitating the pivotable rotation of, the support legs521of the drilling rig mast bottom section520. In other embodiments, the removable plug547may be shaped so as to only partially fill the remaining portion of the oversized pin holes543, such that the second plug surface portion547X is only in partial contact with the second hole portion543X, and which may also enable easier installation and/or removal of the plug547, as illustrated inFIGS. 7D-7EandFIGS. 8D-8Eand described below. It should be noted, however, that the final configuration of the removable plug547—e.g., multiple plug parts, substantially or partially filling the oversized pin hole543, etc.—may be as necessitated by the anticipated loads that may be imparted on the pinned connection550during assembly, erection, disassembly, and/or operation of the drilling rig.

It may be appreciated by those having skill in the art that, depending on the overall pin alignment and mast erection requirements, the relative arrangement of the substantially circular pin hole and the oversized pin hole of the present disclosure may be reversed. For example, in certain illustrative embodiments, the pin holes543of the mast support shoes523may have a substantially circular shape, and furthermore, may be substantially the same size as the removable pin546. Moreover, in other embodiments, the pin hole541of the support legs521may be an oversized pin hole, and may also have a substantially non-circular shape as previously described. Additionally, the when the pin hole541is an oversized pin hole, the removable plug may be adapted to be inserted in the pin hole541, also as previously described.

In some illustrative embodiments of the present disclosure, additional sections of the drilling rig mast may be assembled to the bottom section520after the pinned connection550has been fully assembled—that is, after the removable pin and plug546,547have been installed—and prior to mast erection. For example, additional mast sections, such as the midsections30or130illustrated inFIGS. 1F-1H,FIGS. 1M-1P, andFIGS. 2,3and4A-4H, may be assembled as described in the associated disclosure set forth above.

FIG. 5Fillustrates the drilling rig assembly ofFIGS. 5A-5Eafter the drilling rig mast has been erected. As shown inFIG. 5F, the drilling rig mast may be rotated by the mast erection apparatus522(see,FIGS. 5A-5E) about the pinned connection550during the erection process so that the support legs521are moved from a substantially horizontal orientation to a substantial vertical orientation. Additionally, in some embodiments, the support struts524may be pivoted about the pinned connections540until the pin holes544of the support struts524are aligned with pin holes545of the strut support shoes525. Thereafter, a removable pin551may be inserted through the aligned pin holes544,545so as to create a pinned connection560that attaches the support struts524to the strut support shoes525of the drilling rig substructure511.

It should be noted that when the alignment of the pin holes544with the pin holes545may be problematic—e.g., similar to the situation described with respect to the pin holes541and543above—the pinned connection560may be modified so as to utilize an oversized pin hole on either the support struts524or the struts support shoes525. Furthermore, a pin and plug arrangement similar to the pin546and plug547arrangement described with respect to the pinned connection550above may also be employed, although the specific details may be modified as may be appropriate for the pinned connection560, such as one of the arrangement described below and illustrated inFIGS. 6A-6D. Furthermore, it should also be noted that the pinned structural connections utilizing the pin and plug arrangements described herein may generally be adapted to be used in any instances where the alignment between respective pin holes may be difficult, and should not be restricted only to those applications specifically dealing with drilling rigs, drilling rig mast structures, and/or the erection thereof.

FIGS. 6A-6Eschematically depict one illustrative embodiment of a pin and plug arrangement that may be used to create a novel pinned structural connection in accordance with the present disclosure.FIG. 6Ashows a view of a first pin hole641, which may be representative of any illustrative pin hole in any illustrative structural component that, when used in conjunction with an appropriately designed and sized pin, may be used to facilitate the attachment of one structural component to another. For example, the first pin hole641may be representative of and/or similar to the pin holes541in the lower end of the support legs521of the bottom mast section520illustrated inFIGS. 5A-5Fand described above. Furthermore, the first pin hole641may be a substantially circular pin hole having a size or diameter641D.

FIG. 6Bshows a view of an oversized pin hole643of a second structural component, which may have a substantially non-circular shape, and, in accordance with some illustrative embodiments of the present disclosure, may facilitate an easier alignment of a pinned structural connection as previously described. As illustrated inFIG. 6B, the oversized pin hole643may have a substantially teardrop-like shape, and which may be similar in some respects to the oversized pin holes543of the mast support shoes523illustrated inFIGS. 5A-5Fand described above. It should be appreciated, however, that other shapes may also be used for the oversized pin holes643, as will be further described with respect toFIGS. 7A-7EandFIGS. 8A-8Ebelow. In some embodiments, the teardrop-shaped oversized pin hole643shown inFIG. 6Bmay generally be defined by a shape comprising two overlapping substantially circular shapes653and663, which may be joined by common tangent lines643T therebetween. The first substantially circular shape653may be adapted to rotatably cooperate with a pin646(see,FIG. 6C), and as such may have a size or diameter653D, that, in certain illustrative embodiments, may be substantially the same as the diameter641D of the first pin hole641. Accordingly, when a corresponding pinned connection is fully assembled, loads may be properly transferred and substantially free rotation may be permitted about the pin, as previously described.

The second substantially circular shape663may have a size or diameter663D that is larger than the diameter653D of the first substantially circular shape653, thereby facilitating easier pin hole alignment and pin installation, as noted above. In certain embodiments, the diameter663D may range anywhere from 25-50% larger than the diameter653D, whereas in other embodiments, the size difference between the diameters653D and663D may be less than 25% or greater than 50%, depending on the fit-up and alignment criteria of the first pin hole641and the oversized non-circular pin hole643. Furthermore, in some illustrative embodiments, a centerline653C of the first substantially circular shape653may be offset from a centerline663C of the second substantially circular shape663by a distance643L, which may also provide additional space and/or clearance for pin hole alignment and pin installation.

FIG. 6Cshows a cross-sectional view of a removable pin646having a substantially circular shape that may be used in conjunction with some illustrative embodiments of the pinned structural connections of the present disclosure. The pin646may have a size or diameter646D that is substantially the same as the diameter641D of the first pin hole641, giving due consideration for the requisite gap646G (see,FIG. 6E) that may be necessary to facilitate the free rotation of the assembled pinned connection, as previously discussed, while still enabling the proper transfer of loads from one structural component to another.

FIG. 6Dillustrates one embodiment of a removable plug647of the present disclosure that may be adapted to maintain the position of the removable pin646within the oversized non-circular pin hole643, thereby facilitating load transfer and pivotable rotation between structural components, as previously discussed. Furthermore, in some illustrative embodiments, the removable plug647may be shaped such that the plug647substantially fills a remaining portion of the oversized non-circular pin hole643that is not occupied by the removable pin646, while simultaneously maintaining the position of the pin646. As such, the removable plug647may have a shape that is, in at least some respects, substantially the same as the shape of the oversized non-circular pin hole643. For example, similar to the pin hole643, the plug647may also be defined by a shape comprising two overlapping substantially circular shapes657and667, as shown inFIG. 6D, which may be joined by common tangent lines647T therebetween. However, rather than exactly mimicking the shape of the oversized non-circular pin hole643, that part of the removable plug647that is defined by the first substantially circular shape657will not be present. Instead, the plug647will have a partial “hole” that is at least partially defined by the first substantially circular shape657, the shape and size of which may be adapted so that the plug647may rotatably cooperate with the removable pin646. Furthermore, in some illustrative embodiments, after the removable plug647has been inserted into the oversized hole643, the plug647and the hole643will together define a second pin hole646P, such as the pin hole546P shown inFIG. 5Eand described above. Accordingly, the first substantially circular shape657may have a size or diameter657D that is substantially the same as the diameter653D. Moreover, the second pin hole646P will be occupied by the removable pin646when the pinned structural connection is fully assembled, as shown inFIG. 6E.

In order to ensure a proper fit between the removable plug647and the oversized non-circular pin hole643, a centerline667C of the second substantially circular shape667of the plug647should offset from a centerline657C of the first substantially circular shape657by a distance647L that is substantially the same as the distance643L between the first and second centerlines653C and663C of the pin hole643, as shown inFIG. 6B. Furthermore, the size and shape of the second substantially circular shape667should also be adapted such that the removable plug647non-rotatably engages the oversized pin hole643when the plug647is inserted into the pin hole643proximate the pin646, as shown inFIG. 6E. As such, the size of diameter667D of the second substantially circular shape667may be substantially the same as the diameter663D, giving due consideration to any clearances and/or tolerances that may be required ensure that the installation and/or removal of the plug can readily be accomplished, while still facilitating the proper load transfer from one structural component to another.

FIG. 6Eillustrates the teardrop-shaped pin and plug arrangement of the present disclosure after both the removable pin646and the removable plug647have been installed into the oversized non-circular pin hole643. As shown inFIG. 6E, in certain illustrative embodiments, a gap646G may be present between the pin646and the pin hole643on one side, as well as between the pin646and the removable plug647on the opposite side thereof. The size of the gap646G may typically be sized so as to provide the proper clearances and/or tolerances previously discussed, but has been exaggerated inFIG. 6Efor illustrative purposes only.

FIGS. 7A-7Eschematically depict additional illustrative embodiments of the pin and plug arrangement disclosed herein. As shown inFIG. 7A, an oversized, non-circular pin hole743of a first structural component may be defined by a shape that is a combination of a substantially circular shape753and a substantially rectangular shape763, as well as tangent areas743T therebetween. The substantially circular shape753may have a size or diameter741D that is substantially the same as the size or diameter of a corresponding pin hole of a second structural component (not shown), as previously described with respect toFIGS. 6A-6Eabove.

FIGS. 7B-7Cshow one illustrative embodiment where the removable plug747may substantially completely fill a remaining portion of the oversized non-circular pin hole743that is not occupied by the removable plug746, whereasFIGS. 7D-7Eillustrate an alternative embodiment where a removable plug747A only partially fills the remaining portion of the oversized non-circular pinhole743while maintaining the position of the removable pin746as previously described. As shown inFIGS. 7D-7E, the alternative removable plug747A may be designed such that some areas747C of the plug747A may be trimmed or chamfered for easier installation and/or removal, whereas the circular interface of the plug747A against the pin746may have substantially the same size or diameter741D as previously described. Moreover, either of the removable plugs747,747A may be made up of two or more plug parts (as indicated by dotted lines).

FIGS. 8A-8Cschematically depict yet another illustrative embodiment of the pin and plug arrangement of the present disclosure, where an oversized non-circular opening843and a removable plug847are based on a shape that is substantially defined by a combination of a substantially circular shape853and a substantially triangular shape863. Furthermore,FIGS. 8D-8Eillustrate an alternative removable plug847A where some areas847C of the alternative plug847A may be trimmed and/or chamfered for easier installation and/or removal. As with the removable plugs747and747A above, either of the removable plugs847,847A may be made up of two or more plug parts (as indicated by dotted lines). It should be appreciated that other shape combinations may also be used to define the shape of an oversized non-circular pin hole and removable plug of the present disclosure, while still being within the spirit and teachings of the present disclosure.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for connection two parts of a mast of a drilling rig, the method including: connecting a bottom mast section to a support, the bottom mast section having bottom connection apparatus; moving a second mast section adjacent the bottom mast section, the second mast section releasably connected to a vehicle and said moving done by moving said vehicle, the second mast section having second connection apparatus; and moving the bottom mast section so that the bottom connection apparatus contacts the second connection apparatus and engages the second connection apparatus to secure the bottom mast section to the second mast section. Such a method may one or some, in any possible combination, of the following: releasing the second mast section from the vehicle, and moving the vehicle away from the second mast section; raising with mast raising apparatus the mast comprising the bottom mast section secured to the second mast section; wherein the support is a substructure with raising apparatus, the method further including: raising the substructure with the raising apparatus to move the bottom mast section with respect to the second mast section to facilitate engagement of the bottom connection apparatus with the second connection apparatus; locking together the bottom connection apparatus and the second connection apparatus; the bottom mast section comprises a jaw member connected to the bottom mast section with a throat and a slot, the second connection apparatus comprises an insertion member with a bar, the insertion member sized and located for receipt of an end thereof in the throat of the jaw member and the bar sized and located for receipt within the slot, the method further including moving the bottom mast section to move the end of the insertion member into the throat and to move the bar into the slot; the jaw member has two spaced-apart plates each with a flared portion and a throat defined between the flared portions, the method further including moving an end of the insertion member into the throat; the bottom mast section is two legs each with a jaw member connected thereto, each with a throat and a slot, the second connection apparatus comprises an insertion member with a bar, the insertion member sized and located for receipt of an end thereof in the throat of the jaw member and the bar sized and located for receipt within the slot, the method further including moving the bottom mast section to move the ends of the insertion members into the throats and to move the bars into the slots; the jaw member has two spaced-apart plates each with a flared portion and a throat defined between the flared portions, the method further including moving an end of the insertion member into the throat; wherein the bottom mast section has a primary connection member connected thereto and spaced-apart from the jaw member, the second mast section has a secondary connection member connected thereto, the method further including securing the secondary connection member to the primary connection member; the primary connection member has two spaced-apart plates each with an outwardly flared portion and includes a throat between the outwardly flared portions of the two spaced-apart plates for facilitating entry of part of the secondary connection apparatus between the two spaced-apart plates; the bottom mast section has two legs each with a primary connection member connected thereto and spaced-apart from a jaw member, the second mast section has two legs each with a secondary connection member connected thereto, the method further including securing the secondary connection members to the primary connection members; the primary connection members each have two spaced-apart plates each with an outwardly flared portion and include a throat between the outwardly flared portions of the two spaced-apart plates for facilitating entry of part of the secondary connection apparatuses between the two spaced-apart plates; and/or wherein the support is a substructure with raising apparatus, the method further including raising the substructure with the raising apparatus to move the bottom mast section with respect to the second mast section to engage the bottom connection apparatus with the secondary connection apparatus, and said raising aligning the bottom mast section with the second mast section as the substructure is raised.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a mast system for rig operations, the mast system including: a support, a bottom mast section connected to the support; the bottom mast section having bottom connection apparatus; a second mast section adjacent and connectible to the bottom mast section, the second mast section releasably connected to a vehicle for moving the second mast section; the second mast section having second connection apparatus; and the bottom mast section movable on the support so that the bottom connection apparatus can contact the second connection apparatus and engage the second connection apparatus to secure the bottom mast section to the second mast section. Such a mast system may one or some, in any possible combination, of the following: wherein the support is a substructure with raising apparatus, the substructure with the raising apparatus able to raise the bottom mast section with respect to the second mast section prior to facilitate engagement of the bottom connection apparatus with the second connection apparatus; locking apparatus for locking together the bottom connection apparatus and the second connection apparatus; the bottom mast section having a jaw member connected to the bottom mast section, the jaw member having a throat and a slot, the second connection apparatus comprising an insertion member with a bar, the insertion member sized and located for receipt of an end thereof in the throat of the jaw member and the bar sized and located for receipt within the slot, and the bottom mast section movable to move the end of the insertion member into the throat and to move the bar into the slot; the jaw member has two spaced-apart plates each with a flared portion and a throat defined between the flared portions, the throat for receipt therein of an end of the insertion member into the throat; the bottom mast section having two legs each with a jaw member connected to a leg and each with a throat and a slot, the second mast section having two legs each with a second connection apparatus comprising an insertion member with a bar, the insertion member sized and located for receipt of an end thereof in the throat of a jaw member and the bar sized and located for receipt within a slot of the jaw member, and the bottom mast section movable to move the ends of the insertion members into the throats and to move the bars into the slots; the bottom mast section having a primary connection member connected thereto and spaced-apart from the jaw member, the second mast section having a secondary connection member connected thereto, and the secondary connection member securable to the primary connection member; and/or the bottom mast section has two legs each with a primary connection member connected thereto and spaced-apart from a jaw member, the second mast section has two legs each with a secondary connection member connected thereto, and each secondary connection member securable to an adjacent primary connection member; the primary connection member has two spaced-apart plates each flared out and including a throat defined between the two spaced-apart plates for facilitating entry of part of the second connection apparatus between the two spaced-apart plates.

The systems and methods of the inventions described in the following pending U.S. patent applications, co-owned with the present invention, filed on even date herewith, naming Donnally et al as inventors, fully incorporated herein for all purposes, may be used with certain embodiments of the present invention, the applications entitled: “Drilling Rig Structure Installation And Methods”; “Drilling Rig Drawworks Installation”; and “Drilling Rigs And Erection Methods”.