Offshore drilling rig and a method of operating the same
10570672 ยท 2020-02-25
Assignee
Inventors
Cpc classification
E21B19/004
FIXED CONSTRUCTIONS
International classification
E21B21/00
FIXED CONSTRUCTIONS
Abstract
An offshore drilling rig includes a drill deck, at least one primary well center and a diverter system arranged below the primary well center, a drilling support structure extending upwardly from the drill deck and above the primary well center and the other work center and a first and a second hoisting system supported by the drilling support structure and being adapted for raising or lowering a first and a second load carrier, respectively, and where the offshore drilling rig includes a positioning system adapted for selectively positioning at least the first load carrier in at least a first or a second horizontal position different from the first horizontal position, where the first load carrier in the first horizontal position is positioned above the primary well center, and in the second horizontal position is positioned above the other work center.
Claims
1. An offshore drilling rig comprising; a drill deck; at least two work centers arranged in the drill deck horizontally spaced apart from each other; a drilling support structure extending upwardly relative to the drill deck; a first and a second hoisting system supported by the drilling support structure, the first hoisting system being adapted for raising or lowering a first load carrier at a first horizontal position, and the second hoisting system being adapted for raising or lowering a second load carrier at a third horizontal position that is different from the first horizontal position; the offshore drilling rig comprises a positioning system adapted for: positioning the first load carrier selectively in at least the first horizontal position and a second horizontal position that is different from the first horizontal position, so that the drilling rig may raise or lower tubular equipment through a work center at the first and second horizontal positions via the first hoisting system, and positioning the second load carrier selectively in at least the first and the third horizontal position, so that the drilling rig may raise or lower tubular equipment through a work center at the first and third positions via the second hoisting system wherein the first horizontal position is placed between the second and third horizontal positions and the drilling rig is further arranged to lift tubular equipment suspended from the first and second load carriers through the work center at the first horizontal position using the first and second hoisting systems in cooperation.
2. The offshore drilling rig according to claim 1, wherein the drilling rig is configurable to raise or lower tubular equipment through the work center at the first horizontal position using the first hoisting system and simultaneously raise or lower tubular equipment through a work center at the third horizontal position via said second hoisting system.
3. The offshore drilling rig according to claim 1, wherein the drilling rig is configurable to raise or lower tubular equipment through the work center at the second horizontal position using the first hoisting system without the second hoisting system.
4. The offshore drilling rig according claim 1, wherein the drilling rig is configurable to raise or lower tubular equipment through the work center at the first horizontal position using the second hoisting system without the first hoisting system.
5. The offshore drilling rig according to claim 1, wherein the work center at the first horizontal position is either displaceable between at least the first and the third horizontal positions or the drilling rig comprises at least three work centers where at least the work center at the first horizontal position is fixed.
6. The offshore drilling rig according to claim 1, wherein the first horizontal position is located between the second and the third horizontal position.
7. The offshore drilling rig according to claim 1, further comprising a connecting tool having two opposite ends each being adapted for directly or indirectly connecting to one of the load carriers, so that the connecting tool can be carried by the first and second load carriers, and where the connecting tool has an intermediate load carrier arranged between said two opposite ends and being adapted for carrying a load.
8. The offshore drilling rig according to claim 1, wherein the positioning system is adapted for shifting both said first and second load carriers, being at said first horizontal position or second horizontal positions, to a position next to the first horizontal position, so that the two load carriers are positioned on opposite sides of the first horizontal position to allow both load carriers to operate simultaneously above the first horizontal position.
9. The offshore drilling rig according to claim 1, wherein the first and the second hoisting system of each of the load carriers lift said load carriers via a lifting cable hanging from a cable crown supported by the drilling support structure, and where the positioning system is adapted for shifting at least one of, or each of the cable crowns to and from the first and the second horizontal position relative to that cable crown where the load carrier is positioned above one of the work centers.
10. The offshore drilling rig according to claim 1, wherein the hoisting systems comprises at least one substantially vertically extending linear actuator having a stationary end being fixed with respect to the drill deck, and a travelling end comprising at least one cable sheave, wherein the linear actuator is a hydraulic cylinder.
11. The offshore drilling rig according to claim 1, wherein the work center at the first horizontal position is displaceable between at least the first and second horizontal positions.
12. The offshore drilling rig according to claim 1, wherein the one or more work centers are mounted in a substantially horizontal track in the drill deck, and where the drill deck comprises a work center positioning system adapted for selectively moving and positioning each of the work centers in the horizontal track to the first or the second or the third horizontal position in the drill deck.
13. The offshore drilling rig according to claim 12, wherein the horizontal track is linear at least along a part of it, and where at least one of the work centers is a primary well center with a diverter system arranged below comprising at least one diverter over board tube having a first end being connected to the primary well center and the other end being supported and fixed with respect to the drill deck and having at least one telescopic section between the first and the second end, the telescopic section extending parallel to a linear part of the horizontal track in the drill deck.
14. The offshore drilling rig according to claim 12, and comprising at least one riser tensioning system arranged below the drill deck, and riser tensioners are mounted on a linear riser tensioner track being arranged below, and in parallel to the horizontal track in the drill deck, so that the riser tensioner selectively can be positioned below a selected work center.
15. The offshore drilling rig according to claim 1, wherein two work centers are both well centers.
16. The offshore drilling rig according to claim 15, wherein the well centers are both primary well centers each comprising a diverter system arranged below the primary well center.
17. The offshore drilling rig according to claim 12, wherein the horizontal track is linear at least along a part of the horizontal track, and the positioning system is adapted for shifting each of the cable crowns along a line being parallel to the linear part of the horizontal track in the drill deck.
18. The offshore drilling rig according to claim 1, wherein one of said work centers is a mousehole, or a standbuilding foxhole.
19. The offshore drilling rig according to claim 1, wherein each of the first and second hoisting systems includes a sheave mounted on the drilling support structure, wherein the sheaves are configured to be movable in a horizontal direction along the support structure.
20. A method of performing drilling operations on a well by using the offshore drilling rig according to claim 1, comprising the steps of: configuring one or more of the load carriers so that part of the drilling operation is performed using the first load carrier positioned above the work center at the first or second horizontal positions; and configuring one or more of the load carriers so that the first and second load carriers are positioned on opposite sides of the work center at the first horizontal position and lifting or lowering tubular equipment to the seabed through the work center at the first horizontal position using the first and second hoisting systems in collaboration.
21. A method according to claim 20, wherein the two load carriers are connected by a connecting tool, and where the two load carriers are raised or lowered synchronously when carrying a load via the connecting tool.
Description
THE DRAWING
(1) In the following one or more embodiments of the invention will be described in more detail and with reference to the drawing, where:
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DESCRIPTION OF EXEMPLARY EMBODIMENTS
(12)
(13) From each of the crown sheave clusters 5a and 5b lifting cables 7a and 7b are running down and connecting to a load carrier 8a and 8b each carrying a top drive 9a and 9b at the end of the lifting cables 7a and 7b. Each of the top drives are connected via a retractable dolly 10a and 10b to a vertical track 11a and 11b arranged at the drilling support structure 1. The retractable dollies 10a and 10b are each adapted so that they can position and keep the top drives in different positions above the work centers 3a, 3b, 3c in the drilling deck 2.
(14) In the embodiment shown on
(15) Alternatively the drilling support structure 1 shown on
(16) The embodiment shown in
(17) The skilled person will, however, appreciate that the mere combination of the skidable crown sheave clusters 5a, 5b shown on
(18) For the same reason each cable winch 27a, 27b shown in
(19) In
(20)
(21) This diverter system comprises a diverter housing 13 suspended from the skidbase 25 and supporting the rotary table 14 of the primary well center 3a.
(22) The diverter housing 13 has at least two outlet ports 17a and 17b each being connected to telescopic overboard lines 18a and 18b. This allows the diverter housing 13 to be positioned at different positions along a line defined by the track 4 being parallel to the overboard lines. One such position is shown in
(23) The diverter housing 13 also comprises a mud return outlet port 19 adapted for leading drilling mud from the diverter housing back to the mud process systems via the main mud return line system 20. The mud return line comprises a number of telescopic connectors 21a 21b and 21c arranged at selected positions in order to connect the mud return line to the mud return outlet port 19 on the diverter housing 13.
(24) In
(25) In the following different modes of operating the drilling rig shown in the figures are disclosed in more detail with reference to the relevant figures.
(26) 1. Full redundancy:
(27) With reference to
(28) Full redundancy is achieved by having a transferable, riser-capable primary well center 3a, which may be positioned under either one of the top drives (e.g. 9a or 9b) and load carriers (8a and 8b) of the two fully rated main hoisting- and drilling systems comprising the facility. In this relation the primary well center may be transferred and positioned as mentioned above, with or without one tubular or a string of tubulars 35, such as riser tubes, casings, drilling pipes or the like being supported and/or hanging down from the primary well center, and these tubulars may be either hanging freely down from the primary well center, or they may extend all the way to the sea floor and further extend into the well or be connected to the well at the sea floor. In the latter case a diverter system and a tensioning system as shown on
(29) The riser-capable primary well center 3a shall consist of a rotary table 14 supported by a horizontally transferable skid/trolley 25 that is sunk into a slot in the drill deck 2, so that the rotary table 14 top cover is substantially flush with the drill deck 2 level.
(30) The transferable skid/trolley 25 shall be resting on horizontal skid beams forming a track 4 spanning the width between the two fully rated main hoisting- and drilling systems 9a and 9b.
(31) A diverter housing 13 with telescoping overboard lines (overboard tubing 18a and 18b) and a detachable main flowline (mud return tubing 20) shall be suspended from underneath the said transferable skid/trolley 25.
(32) A transferable/skidding riser tensioning system shall be arranged on horizontal skid beams suspended from underneath the drill deck structure, while spanning the full width between the two fully rated main hoisting- and drilling systems.
(33) Following examples are given for the intended operation to ensure full redundancy e.g. in the case that the one (active) fully rated main hoisting- and drilling system suffers a main equipment breakdown: 1. While drilling, tripping drill pipe or running casing during the riserless tophole sections of the well. 1.1 the drillpipe or casing string is hung off in the power-slips/casing-spider 1.2 the drillpipe or casing string, while being suspended from the power-slips/casing-spider inside the rotary table, will be transferred to the opposite fully rated main hoisting- and drilling system 1.3 drilling, tripping drill pipe or casing running operation may resume on the opposite fully rated main hoisting- and drilling system 2. while running or retrieving riser and BOP 2.1 the riser string and BOP is lowered and hung-off in the riser spider and gimbal, which is resting on top of the rotary table. 2.2 the riser string and BOP, while being suspended from the riser spider and gimbal, will be transferred to the opposite fully rated main hoisting- and drilling system 2.3 running of the riser may resume on the opposite fully rated main hoisting- and drilling system 3. while drilling, tripping drill pipe or running casing through the riser and BOP after this has been connected to the well and the riser has been put in tension 3.1 the drillpipe or casing string is hung off in the power-slips/casing-spider 3.2 the well is secured 3.3 the drillpipe or casing string, while being suspended from the power-slips/casing-spider inside the rotary table, will be transferred to the opposite fully rated main hoisting- and drilling system 3.4 the diverter housing with telescoping overboard lines and detachable main flowline, suspended from below the transferable skid/trolley supporting the rotary table, will be transferred to the opposite fully rated main hoisting- and drilling system 3.5 in fully synchronous motion, the riser string, while being suspended from the riser tensioners will be transferred to the opposite fully rated main hoisting- and drilling system 3.6 drilling, tripping drill pipe or casing running operation may resume on the opposite fully rated main hoisting- and drilling system
(34) The fully redundant dual activity hoisting- and drilling facility illustrated in
(35) With reference to
(36) Fast tripping, casing- or riser running operation is ensured by having two independent and fully redundant hoisting- and drilling systems (top drives 9a and 9b) working in cyclic operation over a common primary well centre 3a.
(37) Each hoisting and drilling system shall consist of a main hoisting system with a horizontally transferable cable crown in the form of a crown sheave cluster arrangement 5a, 5b, allowing the crown sheave cluster 5a, 5b to be horizontally transferred, aligned and locked into position over at least two independent positions/well centers 3a, 3b, 3c on the drill deck 2 below.
(38) Each hoisting system supports a vertically travelling load carrier 8a, 8b arrangement, from which a topdrive 9a, 9b is suspended below on a horizontally extend-/retractable dolly 10a, 10b system for guiding of the topdrive 9a, 9b.
(39) The extend-/retractable dolly 10a, 10b shall have a horizontal travel corresponding with the horizontal travel of the crown sheave cluster 5a, 5b arrangement above, while extending/retracting horizontally in synchronous motion with the skidding crown sheave cluster 5a, 5b arrangement above, ensuring that the hoisting system is kept in true vertical alignment with the cable sheave cluster/load carrier/yoke/hook arrangement and the topdrive 9a, 9b suspended underneath it.
(40) In the following typical examples are given for the intended cyclic operation of the dual hoisting and drilling facility to provide fast tripping, casing or riser running operation:
(41) 1. Tripping/running in the hole: low setback and pipe racking system off-drill deck.
(42) 2. Tripping/running in the hole: setback and pipe racking system on-drill deck.
(43) Fast running or retrieval of the riser and BOP may be performed in a similar cyclic operation, while employing suitable arrangements for facilitating handling of the riser joints to/from the primary well centre 3a with this being in the center position
(44) An added benefit of the invention is the full redundancy provided within this facility in that each hoisting and drilling system will offer full redundancy for the other system in the center operating position, without repositioning of the primary well centre 3a. 3. Synchronous Dual Hoisting:
(45) With reference to
(46) The synchronous hoisting facility is realized by utilizing the two independent and fully redundant hoisting- and drilling systems in a combined synchronous mode of lifting operation above the common primary well center 3a, by using a connecting tool 12.
(47) In
(48) This principle allows for extra heavy duty lifting operation without necessitating any of the two hoisting- and drilling systems to be rated beyond the current design loads of such equipment, where especially the load capacity of the topdrives 9a, 9b are limiting the load capacity of the hoisting systems.
(49) Recurring requests for rigs capable of running extended sections of heavy wall casing strings through deep formations in ultra-deep water may require lifting facilities of 1500 metric tons SWL or beyond.
(50) Current designs of hoisting and drilling systems are limited to approx. 1200 metric tons only, with systems and equipment currently under design and development for up to 1500 metric tons.
(51) Consequently, the next generation of DW drilling rigs may only provide incrementally larger hoisting capacity compared with the current generation of rigs and will therefore restrict well designs to within the 1500 metric tons limit of the next generation of top drives.
(52) However, this invention will allow for hoisting and lowering loads exceeding 2000 metric tons, limited only by the structural integrity and load carrying capacity of the casing and landing string tubulars, running- and handling tools.
(53) A generic ultra-deep subsalt and/or HPHT well development program in ultra-deep water might utilize all aspects of the invention to their full potential through the following steps and transitions between modes of operation:
(54) 1. Dual activity operation for concurrently drilling tophole sections, while running and cementing casing down to and including the 18 casing section.
(55) 2. Dual activity operation for concurrently running riser and BOP, while cementing the 18 casing section, incorporating full redundancy.
(56) 3. Transferring the primary well center 3a with riser and BOP suspended to the center position with subsequent landing of the BOP.
(57) 4. Drilling, tripping and running casing in cyclic operation through riser with primary well center 3a in center position
(58) 5. Running and landing extra-long heavy casing sections in synchronous dual hoisting mode
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(60) A top drive 9a, 9b is suspended from each of the load carriers, and the offshore drilling rig comprises a positioning system adapted for selectively positioning at least the one load carrier or the primary well center selectively in at least a first or a second horizontal position different from the first horizontal position, where the first load carrier in the first horizontal position is positioned above the primary well center, and in the second horizontal position is positioned above the other work center.
(61) In particular,
(62) Generally, a skidable arrangement of equipment allows the displacement, in particular horizontal displacement, of the equipment, e.g. guided by tracks or similar guide means.
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(65) The drilling rig of the present embodiment comprises a drill deck 2 formed on top of a substructure 1597. The substructure comprises a platform supported by legs. The platform defines the drill deck and spans across a moon pool 2122 formed in the hull of the drillship. The drill deck 2 comprises two holes defining well centres 3a,b. The drilling rig comprises a drilling support structure in the form of a mast 1. In the present example, the well centres are located within the footprint of the mast 1. The mast includes two mast portions, each associated with, and adjacent to, one of the well centers. The dual activity mast 1 is supported by the substructure 1597 and extends upwardly from the drill deck 2. The mast comprises two mast portions arranged in a face-to-face configuration, i.e. the respective mast portions are located along the axis connecting the well centres such that both well centres are located between the mast portions. Each mast portion supports a hoisting system, each for lowering a drill string through a respective one of the well centres 3a,b towards the seabed. In the example of
(66) From each of the cable crowns lifting cables 7a,b are running down and connect to a corresponding top drive 9a,b which is suspended from a hook or other load carrier connected to the lifting cables. Each of the top drives is connected via a retractable dolly 10a,b to a vertical track arranged at the mast 1. The retractable dollies are each adapted so that they can position and keep the top drives in different positions above the well centers, as described herein.
(67) Each hoisting system has one or more linear actuators in the form of a hydraulic cylinder 28a,b having its lowermost end fixed with respect to the drill deck and an upper travelling end with a cable sheave. At least one lifting cable has one end extending from another hydraulic cylinder arranged for compensating heave during e.g. drilling operation, and over the travelling cable sheave and further below a second cable sheave being fixed with respect to the mast, and thereafter over the cable crown. The hydraulic cylinders are displaced from the well centres along the direction connecting the well centres and positioned such that both well centres are located between the cylinders of the respective hoisting systems. As can be most easily seen on
(68) As is most easily seen in
(69) The drilling rig further comprises a pipe storage area 1509 for storing pipes in horizontal orientation and catwalk machines 1508 or other horizontal pipe handling equipment for transporting pipes between the storage area 1509 and the well centers 3a,b. To this end, the catwalk machines are aligned with the axis defined by the two well centres.
(70) The drilling rig comprises a setback structure 1812 or similar pipe storage structure for storing stands of tubulars below the substructure 1597 and partly covered by the drill deck 2. The setback structure comprises a support framework 1890 supporting fingerboards having horizontally extending fingers between which tubulars may be stored. The setback structure is arranged so as to allow stands to be moved to/from both well centres from/to the setback. To this end, one or more column rackers 1891 or similar vertical pipe handling equipment may be arranged to move stands into and out of the setback structure 1812. The setback structure 1512 further comprises stand building equipment 1877 configured to build stands from individual pieces of pipe. The setback structure 1812 is located adjacent the moon pool 2122 laterally displaced from the axis defined by the well centers.
(71) Moreover the drilling rig comprises one or more further catwalk machines 1876 configured to feed tubulars from the pipe storage area 1509 or from other storage areas on the opposite side of the mast (towards the aft of the ship) to the stand building equipment 1877. The stand building equipment 1877 may thus receive the pipes from the catwalk machine 1876, bring them in upright orientation, and connect them to other pieces so as to form stands. To this end the stand building equipment may comprise a mousehole through which the stand may be gradually lowered while it is made up until the lowermost end of the stand is at the lowermost level of the setback area 1812, while the uppermost end of the stand is below the drill floor level. The stands may then be received by pipe rackers 1891 and placed in the setback structure 1812 for future use. To this end the pipe rackers are operable to traverse across the setback area, e.g. in the direction parallel to the direction connecting the well centres.
(72) The drilling rig comprises a number of slanted chutes 1892 each for feeding pipes from the setback area 1812 to one of the well centers. To this end the drilling rig may comprise one chute for each well center position, i.e. either the fixed well-center positions or the positions to which a skidable well center can be moved. Alternatively, the chutes may be displacable so as to be selectively aligned with respective well centres. Each chute 1892 receives pipes from one of the pipe rackers 1891 and feed the pipes in a slanted upward direction through a corresponding slit 1785 in the drill floor towards a respective one of the well centres 3a,b, where they are picked up at their uppermost end by the corresponding hoisting system and lifted through the slit 1785 until they are vertically suspended above the corresponding well center. To this end, the drilling rig further comprises pipe handling equipment 1786 operable to guide the pipes while they are being lifted through the slit 1785. The slits 1785 are elongated and point away from the axis connecting the well centers and towards the side where the setback area 1812 is positioned. To allow for the pipes to be presented in this fashion, the driller's cabin 1534 is positioned at an elevated level above the slits 1785. One or more further pipe handling devices, such as iron roughnecks 1727, may be located between neighbouring slits and underneath the driller's cabin, e.g. such that each iron roughneck may service two well center positions.
(73) The drilling rig comprises another storage area 1515 below the drill deck 2 and configured for storing risers in a vertical orientation. The riser storage area 1515 is located adjacent the moon pool 2122, e.g. on the side of the moon pool opposite the setback structure 1812. The risers may then be moved, e.g. by means of a gantry crane 2298 and respective chutes 2294 or other suitable pipe feeding equipment through holes 1681 in the drill deck floor. The riser feeding holes 1681 may be covered by removable plates, hatches or similar covers, as illustrated in e.g.
(74) As the stands of tubulars and the risers are stored below the drill deck, and since the cat walk machines 1508 extend towards opposite sides from the well centers, and since the mast structure 1 is located on one side of the well centres, the drill deck provides a large, unobstructed deck area on the side of the well centres opposite the mast. This area provides unobstructed access to both well centres and is free of pipe handling equipment. Consequently, these areas may be used as working area, e.g. for rigging up suspendable auxiliary equipment, and/or for positioning on-deck auxiliary equipment. Moreover, at least parts of the setback structure 1812 may be covered by a platform 1788 so as to provide additional storage or working area.
(75) Although some embodiments have been described and shown in detail, the invention is not restricted to them, but may also be embodied in other ways within the scope of the subject matter defined in the following claims. In particular, it is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention.
(76) The mere fact that certain measures are recited in mutually different dependent claims or described in different embodiments does not indicate that a combination of these measures cannot be used to advantage.
(77) It should be emphasized that the term comprises/comprising when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.