Patent Publication Number: US-2021172576-A1

Title: Improved elevated structure-mounted lighting system

Description:
TECHNICAL FIELD 
     The present application relates to lighting systems, and more particularly, to lighting systems that may be used for a drilling application. 
     BACKGROUND 
     Lighting systems for drilling rigs and their surrounding areas are critical to ensure continuous and safe operation of well sites. To ensure even and effective lighting of the well site, lighting systems have previously been installed on the uppermost portion of the drilling rig, also referred to as the “crown” of the rig. Prior art crown-mounted lighting systems developed for oil rigs are limited in several ways. Their designs are complicated and designed for specific rigs or rig types. Typically, once they are designed for a particular rig or a particular type of rig, the lighting systems designs are limited and are not able to be adapted for other uses. 
     Prior art lighting systems for drilling rigs are fixed, monolithic structures that are typically crown or frame systems, with a single size and layout accommodating one type of light and rig. Because they are a single structural unit, they are heavy and typically require cranes along with multiple workers for installation, removal, and adjustments. A typical rig lighting frame system may require between 6 and 12 hours for installation. Further, before a derrick can be moved, the lighting systems must be removed—again with all of the necessary equipment and personnel—and a similar amount of time may be required for uninstallation. These installation and uninstallation times extend the time needed between rig deployments. Due to the high cost of operating a rig, any such delay is extremely inefficient for the operator of a wellsite. These factors also increase the time required to be spent on maintaining these systems, which also increases safety risk. 
     SUMMARY 
     An improved elevated structure-mounted lighting system is disclosed. In addition to being used on rigs, embodiments of the lighting system may be used with different applications, including for drilling, production, refineries, frac sites, construction, and other industrial applications that may use tower/mast type equipment. The improved elevated structure-mounted lighting system may accommodate any style or design of crown section of a drilling rig and may be mounted on a pole or independent mount system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention are described with reference to the following figures. The same numbers are used throughout the figures to reference like features and components. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale. 
         FIG. 1  illustrates a prior art crown-mounted frame-based lighting system. 
         FIG. 2  shows a three-dimensional isometric view of three embodiments of the improved elevated structure-mounted lighting system that are depicted relative to a crown deck. 
         FIG. 3  illustrates an elevation view of three embodiments of the improved elevated structure-mounted lighting system that are depicted relative to a crown deck. 
         FIGS. 4A and 4B  are enlarged views of two embodiments of a light fixture and cap of a light unit of the improved elevated structure-mounted lighting system. 
         FIG. 5  is an enlarged view of an embodiment of a light fixture and a cap of a light unit illustrating different positions of the light fixture. 
         FIG. 6  is a side view of an embodiment of a light fixture mounting pole. 
         FIG. 7A  is a side view of the embodiment of  FIG. 6  with a light fixture that is attached to rails. 
         FIG. 7B  is a side view of the embodiment with a single mounting plate. 
         FIG. 8  is a perspective view of the embodiment of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a prior art lighting system  100 . The prior art lighting system is built from a single frame  120  which includes multiple frame lights  130 . The frame lights  130  are rigidly fixed onto the frame  120  and cannot be adjusted or repositioned. The frame  120  includes the electrical connections for the lights. The frame  120  may be installed on the crown  110 , or top, of a drilling rig such that the ground around the drilling rig is illuminated when in use. 
       FIG. 2  shows a three-dimensional isometric view and  FIG. 3  shows an elevation view of three embodiments of the improved elevated structure-mounted lighting system  200  that are depicted relative to a crown deck. The embodiments of the lighting system  200  may be mounted on the crown deck of a drilling rig or on other elements of a frame structure. The lighting system  200  is lightweight in design and may be manufactured using any type of metal, including aluminum, steel, carbon, hot roll, etc. The frame structure may be hollow to reduce weight. The lighting system is also modular, which allows it to be assembled on site without the use of heavy equipment, cranes, harnesses, supports, cables, etc. This reduces the risk of accidents and the time and costs associated with the same. In an embodiment, a pole-mounted design may be set up by two people in under one hour. The system may accommodate a variety of different light types, with differing luminosities and power consumption, that may be selected based on the particular application. Variations of light types may include combustion-proof and/or LED lights. 
     The lighting system  200  is modular and assembled using multiple standalone pieces that may be configured to different structures. Three lighting unit embodiments from  FIGS. 2 and 3  are shown in an I-shape  210 , T-shape  220 , and L-shape  230 , but this is not limiting and other configurations or modifications may be used, due in part to the modular nature of the system. There is no master frame or master support structure, which allows for configurability and customization. 
     As shown in  FIG. 3 , the light units  210 ,  220 , and  230  may include a mounting pole  240 , a bracket for a top rail  242 , a bracket for a bottom rail  244 , a cap  246 , and a light fixture  248 . The bracket for a top rail  242  and bracket for a bottom rail  244  may be used to attach the light mounting pole  240  to rails  205  of a crown deck of a drilling rig using U-shaped bolts or straps, as shown in  FIG. 2 . The straps are wrench-type straps that may be made out of a plastic composite. In another embodiment, the mounting pole  240  may be welded directly to the drilling rig crown or other structure. 
     In the alternative embodiment shown in  FIG. 6 , mounting pole  240  may be attached to the crown deck or other structure using brackets  300  and  310  that attach to top rail  242  and bottom rail  246  respectively. In this particular embodiment, bracket  300  comprises a top mount plate  320  and a top rail clamp  330 , while bracket  310  comprises bottom mount plate  360  and clamp plate  370 . One benefit of this alternative embodiment is allowing the use of shorter mounting poles, which thereby reduces the overall weight of the system. As shown more clearly in  FIG. 7A , top mount plate  320  includes a vertical portion  322  that is substantially parallel to the central axis of mounting pole  240  and a horizontal portion  324  that is substantially parallel to the top surface of top rail  242 . Similarly, top rail clamp  330  includes a vertical portion  332  that is substantially parallel to the central axis of mounting pole  240  and a horizontal portion  334  that is substantially parallel to the top surface of top rail  242 . The horizontal portions of top mount plate  320  and top rail clamp  330  are connected together, as for example by one or more bolts, as shown in  FIG. 7 . Alternatively, as shown in  FIG. 7A , top mount plate  320  and top rail clamp  330  may be combined into a single component that hooks over the top of top rail  242 . 
     Mounting pole  240  is held in place and attached to top rail  242  by the use of one or more bolts  340 , which are inserted through both top mount plate  320  and top rail clamp  330 . In the embodiment of  FIG. 7A  with no separate top rail clamp, bolt(s)  340  are inserted through both vertical portions of top mount plate  320 . 
     Mounting pole  240  may be further held in position using one or more tube clamps  350 , which are bolted or otherwise connected to top mount plate  320  and/or bottom mount plate  360 . 
     Also as shown in  FIG. 7A , bottom mount plate  360  includes a vertical portion  362  that is substantially parallel to the central axis of mounting pole  240 . Optionally (but not shown), bottom mount plate  360  may also include a horizontal portion that is substantially parallel to the bottom of bottom rail  244 . Clamp plate  370  also includes a vertical portion  372  that is substantially parallel to the central axis of mounting pole  240 . Also, optionally (but not shown), clamp plate  360  may include a horizontal portion that is substantially parallel to the bottom of bottom rail  244 . Alternatively, as shown in  FIG. 7B , bottom mount plate  360  and clamp plate  370  may be combined into a single component  336  that hooks over the bottom of bottom rail  242 . In  FIG. 7B , bolt  340  may be optional. 
     Mounting pole  240  is held in place and attached to bottom rail  244  by the use of one or more bolts  380 , which are inserted through both bottom mount plate  360  and clamp plate  370 . In the embodiment of  FIG. 7A  with no separate clamp plate, bolt(s)  380  are inserted through both vertical portions of bottom mount plate  360 . Mounting pole  240  may be further held in position using tube clamp  350 , which is also bolted or otherwise connected to mount plate  320 . 
     As shown in  FIG. 6 , top mount plate  320  and bottom mount plate  360  are also connected to each other, using one or more bolts  390  or other fastening devices, providing further stability and for this alternative embodiment. 
     In addition, top mount plate  320  and bottom mount plate  360  may be configured with one or more vertically extending apertures  392  (as shown in  FIG. 8 ), allowing the two mount plates to be moved vertically in relation to each other, while still providing the ability to insert bolt(s)  390  or other fastening devices through both mount plates. The vertically extending apertures  392  thus allow this alternative embodiment to be used on crown decks or other structures with a wide range of different dimension and configurations. 
     The light fixture  248  connects structurally and electrically to the cap  246 , which houses wiring to accommodate any light fixture  248  that may be attached. Referring to  FIGS. 4A and 4B , the light fixture  248  may be bolted to the cap  246 , but is preferably connected to the cap using a pin-based engagement. The pins  250  may be removable. Once the light fixture  248  is engaged with the cap  246  such that pinholes  252  are aligned, one or more pins  250  may be inserted to securely connect the light fixture  248  to the cap  246 . Because the pins  250  are removable, the light fixture  248  may be disconnected and removed from the cap  246  by removing the pins  250 . The light fixture  248  and cap  246  are preferably structured so that the light fixture  248  may be engaged with the cap  246  to face outward (as shown in  FIG. 4A ) or to face inward (as shown in  FIG. 5 ). This may be accomplished by aligning the pinholes  252  in at least a first position or in a second position. The light fixture  248  may be configured in the outward position for use and installed in the inward position for transport. 
     Based on the design, more than two positions may be contemplated. For example, as shown in  FIG. 7A , mounting pole  240  may be configured with a plurality of pinholes  252 . In this embodiment, where mounting pole  240  is cylindrical, pinholes  252  may be radially spaced around the circumference of mounting pole  240 . In addition, light fixture  248  may be connected to cap  246  by the use of light bracket  400 . In this embodiment, as shown in  FIG. 7A , light bracket  400  comprises a generally cylindrical portion  402 , which extends telescopically into at least the upper portion of mounting pole  240 . In addition, cylindrical portion  402  is configured with one or more pinholes  404  which are configured to be aligned with the one or more pinholes  252  on mounting pole  240 . In this way, pin(s)  250  may be used to maintain light fixture  248  in a plurality of different positions simply by removing pin  250  rotating the light bracket  400  until pinhole  404  aligns with a different pinhole on mounting pole  240 , and reinserting pin  250  in the new position. 
     Safety cables connected between the light fixture  248  and cap  246  may be used as a backup in the event that pins  250  back out or are sheared during an extreme weather condition. 
     With prior art lighting systems, when a square frame is mounted, the lights are also fixed and cannot be moved as they are attached to the frame as a single unit. In contrast, in the improved elevated structure-mounted lighting system, each light may be mounted on a standalone base, and does not have to be attached to a master frame. Referring back to  FIGS. 2 and 3 , multiple light units  210 ,  220 , and  230  may be installed on a crown in different configurations. 
     Accordingly, the lights may be individually shifted up, down, left, or right. Based on the location of a light unit  210 ,  220 , or  230 , if more surface area is required to be lit on a particular side, the lights may be configured and directed in that direction, or the light pole may be adjusted to achieve optimal surface lighting. Individual LED bulbs may be angled in a way to produce the greatest amount of light without dissipation. In an embodiment, efficient lights allow the lighting system to be run from 120V or 240V. The lights may come with dimmer, solar, and/or sensor options. These factors allow for lighting to be achieved more efficiently than prior art lighting systems. 
     Metal safety nets may also be affixed to the crown below the light units  210 ,  220 , and  230 . In additional to its modular frame design, the lighting system  200  may use consistent nut and bolt sizes, which allows flexibility and interoperability in its structural design and assembly. 
     The modular nature of the improved elevated structure-mounted lighting system also allows for it to be serviced or adjusted while it is erect and installed. There is a single cable to connect to a power source from crown to ground. At the lighting junction box, 12 quarter turn Appletons may be used. Woodhead plugs may also be used on the junction box. Further, the improved elevated structure-mounted lighting system does not have to be removed or taken down when the derrick or other applications are being transported or moved, which is allowed because the cords may be disconnected, rather than removed, during transport. Once transport is complete, the cords may be reconnected. Other features, such as an explosion-proof control panel on the ground with power switches may be used. As noted above, due to the high costs of rig operation, reducing time for installation and maintenance and improving safety are significant factors to reducing operation costs. 
     Many modifications and other implementations beyond those set forth herein will be apparent having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the systems and methods described herein are not to be limited to the specific implementations disclosed and that modifications and other implementations are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense and not for purposes of limitation.