Drilling rig with a top drive system operable in a drilling mode and a tripping mode

Abstract

A drilling rig is adapted to perform drilling and/or other wellbore related activities. The drilling rig includes a drilling tower, a drill floor with a well center, a slip device arranged at the well center, a tubulars connection makeup and breaking device near the well center, and a top drive system. The top drive system includes a traveling carriage that is vertically mobile along one or more vertical rails of the drilling tower by a vertical motion drive. The system also includes a top drive unit supported by said carriage and including a top drive motor and a rotary torque output member. The system further includes a tripping operation elevator that is adapted to be engageable with a drilling tubulars string or drilling tubulars stand, e.g. with the top end thereof, in order to perform tripping operations. The top drive unit and the tripping operation elevator are each mobile relative to the traveling carriage, and wherein the top drive system is provided with one or more actuators adapted to cause said relative motion of the top drive unit and of the tripping operation elevator so as to provide a drilling mode and a tripping mode.

Claims

1. A drilling rig adapted to perform drilling and/or other wellbore related activities, the drilling rig comprising: a drilling tower, wherein the drilling tower is a mast having a U-shaped horizontal cross section with a left-hand mast wall, a rear mast wall, and a right-hand mast wall, and with an open front; a drill floor with a well center positionable above a wellbore; a slip device arranged at the well center and adapted to suspend a drilling tubulars string in the wellbore; a tubulars connection makeup and breaking device near the well center; a top drive system; a vertical motion drive adapted to cause vertical motion of the top drive system relative to the drilling tower in order to perform drilling and tripping operations; and a fingerboard device adapted to store drilling tubulars stands, wherein the drilling tower is provided with one or more vertical rails parallel to a vertical firing line that extends through the well center, wherein the top drive system comprises: a traveling carriage that is vertically mobile along said one or more vertical rails of the drilling tower by means of said vertical motion drive; and a top drive unit supported by said traveling carriage and comprising a top drive motor and a rotary torque output member that is adapted to be engaged with a top end of a drilling tubulars string extending in said firing line through the well center to impart torque to said drilling tubulars string in order to perform drilling operations, wherein the top drive system further comprises a tripping operation elevator that is adapted to be engaged with a drilling tubulars string or a drilling tubulars stand in order to perform tripping operations, wherein the top drive unit is movable relative to the travelling carriage between a non-operative position in which the rotary torque output member of the top drive unit is radially outward of the firing line and closer to the rear wall of the mast, and an operative position in which the rotary torque output member of the top drive unit is aligned with the firing line, wherein the tripping operation elevator is movable relative to the traveling carriage between a non-operative position in which the tripping operation elevator is radially outward of the firing line, and an operative position in which the tripping operation elevator is aligned with the firing line, wherein the top drive system is provided with one or more actuators between the traveling carriage, the top drive unit, and the elevator, said one or more actuators being configured to drive the top drive unit to move between the non-operative position of the top drive unit and the operative position of the top drive unit relative to the traveling carriage, and to drive the tripping operation elevator to move between the non-operative position of the tripping operation elevator and the operative position of the tripping operation elevator, so as to provide: a drilling mode; and a tripping mode, wherein, in said drilling mode, the top drive unit is in the operative position thereof with the rotary torque output member being aligned with said firing line and the tripping operation elevator is in the non-operative position thereof remote from said firing line, wherein, in said tripping mode, the tripping operation elevator is in the operative position thereof being aligned with said firing line and the top drive unit is in the non-operative position thereof in which the rotary torque output member of the top drive unit is moved out of said firing line and is positioned radially outward of said firing line and closer to the rear wall of the mast compared with the operative position of the top drive unit in the drilling mode, wherein the top drive system is embodied such that, in said tripping mode, an unobstructed zone is present vertically above the tripping operation elevator allowing the top drive system to be lowered, with the top drive unit being in said non-operative position thereof, along a drilling tubulars stand in the firing line above the well center, at least so that the top drive system is below the top end thereof, whilst the drilling tubulars stand is disconnected by means of the tubulars connection makeup and breaking device, and wherein the top drive system is embodied such that, in said tripping mode and with the top drive system lowered at least below the top end of said drilling tubulars stand, said drilling tubulars stand is removable from the firing line, primarily in a lateral direction, to allow for placement of said drilling tubulars stand in said fingerboard device.

2. The drilling rig according to claim 1, wherein said top drive unit and said tripping operation elevator are mechanically linked so as to move in unison when operating said one or more actuators to switch between said drilling mode and said tripping mode.

3. The drilling rig according to claim 1, wherein said top drive unit is supported on the traveling carriage by a parallelogram mechanism with horizontal pivot axes, said parallelogram mechanism comprising at least one pair of upper and lower support arms that are each pivotally connected to said carriage and said top drive unit.

4. The drilling rig according to claim 3, wherein, in the drilling mode, the pivot axes of the arms of the parallelogram mechanism supporting the top drive unit are in a vertical plane.

5. The drilling rig according to claim 1, wherein the tripping operation elevator is suspended by one or more links that are each connected at an upper end thereof from a pivotal elevator support arm that is pivotally connected to said traveling carriage about a horizontal pivot axis.

6. The drilling rig according to claim 5, wherein the top drive system further comprises a stabilizer rod for a link from which the tripping operation elevator is suspended, said stabilizer rod having one end that pivotally connected to the link and another end that is pivotally connected to the carriage so as to form a parallelogram mechanism in combination with the pivotal elevator support arm.

7. The drilling rig according to claim 5, wherein, in the tripping mode, the links of the tripping operation elevator are in a vertical plane.

8. The drilling rig according to claim 1, wherein said top drive unit is supported on the traveling carriage by a parallelogram mechanism with horizontal pivot axes, said parallelogram mechanism comprising at least one pair of upper and lower support arms that are each pivotally connected to said carriage and said top drive unit, and wherein the tripping operation elevator is suspended by one or more links that are each connected at an upper end thereof from a pivotal elevator support arm that is pivotally connected to said traveling carriage about a horizontal pivot axis, and wherein said elevator support arm is integral with a support arm of said parallelogram mechanism.

9. The drilling rig according to claim 1, wherein the vertical motion drive comprises a crown block assembly with sheaves, said crown block being mounted on said tower, and further comprises a drawworks with a winch and winch driven cable, and wherein the traveling carriage is provided with sheaves, said traveling carriage being suspended from the crown block by said cable passing over said sheaves.

10. The drilling rig according to claim 9, wherein the sheaves on the traveling carriage are assembled in a left-hand sheave assembly and a right-hand sheave assembly with said unobstructed zone passing between said sheave assemblies.

11. The drilling rig according to claim 1, wherein the top drive unit comprises a top drive frame supporting the top drive motor and the rotary output member, and wherein said top drive unit is supported on the traveling carriage by a parallelogram mechanism with horizontal pivot axes, said parallelogram mechanism comprising at least one pair of upper and lower support arms that are each pivotally connected to said carriage and said top drive unit, and wherein the top drive frame is connected to the carriage by said parallelogram mechanism, and wherein the one or more actuators are mounted between the traveling carriage and the top drive frame or between the carriage and the parallelogram mechanism.

12. The drilling rig according to claim 1, wherein the tower is a mast having a U-shaped horizontal cross section with a left-hand mast wall, a rear mast wall, and a right-hand mast wall, and with an open front, and wherein said mast comprises left-hand and right-hand vertical front posts and rear corner posts, with each front post being connected by bracings to a respective rear corner post to form the respective side wall of the mast and said rear corner posts being connected to each other by bracings to form the respective rear wall of the mast.

13. The drilling rig according to claim 1, wherein the carriage travels between two vertical rails that extend in a vertical plane that encompasses the firing line.

14. The drilling rig according to claim 1, wherein the carriage comprises a structural frame with a left-hand carriage frame member and a right-hand carriage frame member interconnected by one or more transverse frame members, wherein said transverse frame members extend rearward of said firing line to provide said unobstructed zone allowing removal of the tubulars stand in a forward direction.

15. The drilling rig according to claim 1, wherein the top drive system further comprises a drilling operation elevator, distinct from the tripping operation elevator, which drilling operation elevator is adapted to retain a drilling tubular in vertical orientation below the rotary output member of the top drive unit in its operative position, wherein said drilling operation elevator is suspended from the top drive unit.

16. The drilling rig according to claim 1, wherein a left-hand fingerboard device is mounted to a left-hand side of the mast and a right-hand side fingerboard device is mounted to a right-hand side of the mast.

17. The drilling rig according to claim 1, wherein the drilling rig comprises a tubulars racking device comprising one or more mobile tubulars gripper assemblies with one or more grippers adapted to grip a tubular or tubulars stand and move the tubular or tubulars stand between the fingerboard device and the firing line.

18. The drilling rig according to claim 1, wherein the drilling rig comprises a tubulars racking device comprising one or more mobile tubulars gripper assemblies with one or more grippers adapted to grip a tubular or tubulars stand and move the tubular or tubulars stand between the fingerboard device and the firing line, wherein a left-hand fingerboard device is mounted to a left-hand side of the mast and a right-hand side fingerboard device is mounted to a right-hand side of the mast, and wherein the tubulars racking device comprises a structural frame supported by the tower embodied as a U-shaped horizontal cross-section mast, at an elevated position thereon relative to the drill floor, wherein said structural frame comprises one or more horizontal rails extending across the front side of the mast and across the front sides of the fingerboard devices, said tubulars racking device further comprising a mobile tubulars gripper assembly guided by said one or more rails and provided with one or more grippers and adapted to grip a tubular stand and move the tubulars stand between the fingerboard devices and the firing line, and wherein the tubulars racking device is embodied to allow for passage of the top drive system in its drilling mode and in its tripping mode.

19. The drilling rig according to claim 1, wherein a mobile tubulars gripper assembly of the tubulars racking device is provided with an auxiliary winch and a winch driven cable, preferably the assembly being movable both in X and Y orthogonal directions in a horizontal plane, wherein the mobile tubulars gripper assembly is positionable at least in a position such that the winch driven cable is aligned above the well center and can be lowered to the well center on the drill floor to perform lifting operations above or near the well center using the auxiliary winch on the mobile tubulars gripper assembly of the tubulars racking device.

20. The drilling rig according to claim 1, wherein the tower is provided at the top thereof with an auxiliary crane having a base secured to the tower and a crane boom connected via a vertical axis slew bearing to the base allowing to slew the boom, and wherein the auxiliary crane comprises a winch and a winch driven cable for hoisting of objects, wherein the auxiliary crane is embodied such that the winch driven cable can be passed vertically along the firing line down to the well center in the tripping mode of the top drive system so as to allow for use of the auxiliary crane for lifting operations at or near, or towards and away from, the well center.

21. The drilling rig according to claim 20, wherein the auxiliary crane is a jib or cantilever crane, wherein the boom extends permanent in horizontal direction and wherein a trolley is displaceable along the boom, with the trolley being provided with a sheave and/or the winch, and the trolley at least being positionable so that the winch driven cable passing over said sheave and/or depending from the winch is aligned with the firing line, and a position remote from said firing line position.

22. A method for tripping out a drilling tubulars string from a wellbore, wherein use is made of the drilling rig according to claim 1, comprising the steps of: suspending a drilling tubulars string in a wellbore by means of the slip device; bringing the top drive system in said tripping mode; lowering the traveling carriage to an initial engagement level and connecting the tripping operation elevator with a top end of the suspended drilling tubulars string; releasing the slip device and lifting the carriage, so as to pull up a tubulars stand above the well center; engaging the slip device to suspend the drilling tubulars string; and with the top drive system remaining in said tripping mode, lowering the carriage so as to move the tripping operation elevator to said initial engagement level for renewed pull up of a next tubulars stand, wherein the tripping operation elevator slides along the tubulars stand in the firing line at least till the top drive system is below the top end thereof, wherein in which method at least one of the following steps is performed in time overlap with said lowering of the carriage: disconnecting the lifted tubulars stand from the suspended drilling tubulars string by means of said tubulars connection makeup and breaking device near the well center; removing the disconnected tubulars stand from the firing line, primarily in a lateral direction; placing the drilling tubulars stand in said fingerboard device; and when the tripping operation elevator has reached said initial engagement level, connecting the tripping operation elevator to the top end of the suspended drilling tubulars string.

23. The method according to claim 22, wherein the disconnected tubulars stand is moved into the fingerboard by a tubulars racking device, and wherein said one or more grippers, at least one gripper, is engaged with the tubulars stand in the firing line after the tripping operation elevator has descended below the level of the respective gripper.

24. A drilling rig adapted to perform drilling and/or other wellbore related activities, said drilling rig comprising: a drilling mast having a U-shaped horizontal cross section with a left-hand mast wall, a rear mast wall, and a right-hand mast wall, and with an open front side, said mast being composed of interconnected mast sections; a drill floor with a well center; a top drive system; a vertical motion drive adapted to cause vertical motion of the top drive system relative to the drilling mast in order to perform drilling and tripping operations; and a fingerboard device adapted to store drilling tubulars stands in vertical orientation, wherein the mast is provided with one or more vertical rails parallel to a vertical firing line that extends through the well center, wherein the top drive system comprises: a traveling carriage that is vertically mobile along said one or more vertical rails of the drilling mast by means of said vertical motion drive; and a top drive unit supported by said carriage and comprising a top drive motor and a rotary torque output member adapted to be engageable with a top end of a drilling tubulars string extending in the firing line through the well center to impart torque to said drilling tubulars string in order to perform drilling operations, wherein the top drive system further comprises a tripping operation elevator that adapted to be engageable with a drilling tubulars string or drilling tubulars stand in order to perform tripping operations, wherein the top drive unit is movable relative to the travelling carriage between a non-operative position in which the rotary torque output member of the top drive unit is radially outward of the firing line and closer to the rear wall of the mast, and an operative position in which the rotary torque output member of the top drive unit is aligned with the firing line, wherein the tripping operation elevator is movable relative to the traveling carriage between a non-operative position in which the tripping operation elevator is radially outward of the firing line, and an operative position in which the tripping operation elevator is aligned with the firing line, wherein the top drive system is provided with one or more actuators between the traveling carriage the top drive unit, and the elevator, said one or more actuators being configured to drive the top drive unit to move between the non-operative position of the top drive unit and the operative position of the top drive unit relative to the traveling carriage, and to drive the tripping operation elevator to move between the non-operative position of the tripping operation elevator and the operative position of the tripping operation elevator, so as to provide: a drilling mode; and a tripping mode, wherein in said drilling mode the top drive unit is in the operative position thereof with the rotary torque output member being aligned with the firing line and the tripping operation elevator is in the non-operative position thereof forward from said firing line, wherein in said tripping mode the tripping operation elevator is in the operative position thereof being aligned with the firing line and the top drive unit is in the non-operative position thereof in which the rotary torque output member of the top drive unit is moved out of said firing line and is positioned radially outward of said firing line and further towards the rear wall of the mast compared with the operative position of the top drive unit in the drilling mode, wherein the top drive system is embodied such that, in said tripping mode, an unobstructed zone is present vertically above the tripping operation elevator allowing the top drive system to be lowered, with the top drive unit being in said non-operative position thereof, along a drilling tubulars stand in the firing line above the drill floor, at least so that the top drive system is below the top end thereof, and wherein the top drive system is embodied such that, in said tripping mode and with the top drive system lowered at least below the top end of said drilling tubulars stand, said drilling tubulars stand is removable from the firing line, primarily in a lateral and in a forward direction, to place said drilling tubulars stand in said fingerboard device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings:

(2) FIG. 1 shows in perspective view a drilling rig according to the invention,

(3) FIG. 2 shows the rig of FIG. 1 in side view,

(4) FIG. 3 shows in perspective view an upper part of the rig of FIG. 1 on a larger scale,

(5) FIG. 4 shows the part of the rig of FIG. 3 in side view,

(6) FIG. 5a illustrates in side view the automated racking device of the rig of FIG. 1,

(7) FIG. 5b illustrates a part of the automated racker of the rig of FIG. 1,

(8) FIG. 6 illustrates in front view the automated racking device of the rig of FIG. 1,

(9) FIG. 7 shows the crown mast section of the rig of FIG. 1,

(10) FIG. 8 shows a part of the mast, the top drive system, and fingerboard devices of the rig of FIG. 1,

(11) FIGS. 9a-d show various views on the top drive system of the rig of FIG. 1 in the tripping mode,

(12) FIG. 10 shows in a perspective view similar to FIG. 9a the top drive system in the tripping mode,

(13) FIG. 11 shows in a side view similar to FIG. 9b the top drive system in the tripping mode,

(14) FIG. 12 shows in a front view similar to FIG. 9c the top drive system in the tripping mode,

(15) FIG. 13 shows in horizontal cross section from above similar to FIG. 9d the mast and the top drive system in the tripping mode,

(16) FIGS. 14a-d show various views on the top drive system of the rig of FIG. 1 in the drilling mode,

(17) FIG. 15 shows in a perspective view similar to FIG. 14a the top drive system in the drilling mode,

(18) FIG. 16 shows in a side view similar to FIG. 14b the top drive system in the drilling mode,

(19) FIG. 17 shows in a front view similar to FIG. 14c the top drive system in the drilling mode,

(20) FIG. 18 shows in horizontal cross section from above similar to FIG. 14d the mast and the top drive system in the drilling mode,

(21) FIG. 19 shows in a perspective view a detail of the top drive system of the rig of FIG. 1,

(22) FIGS. 20-25 illustrate the tripping of a drill string by means of the rig of FIG. 1.

DETAILED DESCRIPTION OF EMBODIMENTS

(23) FIG. 1 shows a drilling rig 1 for drilling a wellbore and for other wellbore related activities, e.g. for plug and abandonment of non-productive wellbores, well intervention, etc.

(24) In this example the rig 1 is a mobile rig composed of modules that are transportable by road vehicles from one drilling site to another. The invention and aspects thereof may however also be of use in non-mobile rigs and/or non-modular rigs, e.g. rigs with a derrick structure over a moonpool on an offshore drilling vessel.

(25) The rig 1 comprises a drilling tower 10, which is embodied here as a mast. In another embodiment the tower 10 can be embodied as a derrick.

(26) The mast 10 has a U-shaped horizontal cross section with a left-hand mast wall 11a, a rear mast wall 11b, and a right-hand mast wall 11c, and with an open front side 12.

(27) The mast comprises left-hand and right-hand vertical front posts 13a, 13d, rear corner posts 13b, 13d. Each front post 13a, d is connected by bracings, here a combination of horizontal and diagonal bracings, to a respective rear corner post 13b, 13c to form the side walls 11a, 11c of the mast. The rear corner posts 13b, 13c are also connected by bracings.

(28) In view of the transportation of the drilling rig 1 the mast 10 is composed of multiple sections, including a crown section 14 at the top of the mast, a floor section 15 at the lower, and one or more intermediate mast sections 16. For example, as here, the vertical posts 13a,b,c,d are provided with connector members to secure the mast sections one on top of the other.

(29) In this example the floor section 15 is provided at its lower end with a pivot structure 15a defining a horizontal pivot axis allowing the mast 10, preferably assembled in horizontal state, to be erected.

(30) The rig 1 comprises a drill floor 20 with a well center 21.

(31) As is preferred a slip device 22 is arranged at the well center 21, e.g. a mechanized and remotely controllable slip device with one or more mobile slip members. The slip device 22 is adapted to support a drill string or other tubular string that extends into the wellbore.

(32) On the drill floor 20 further a tubulars connection makeup and breaking device 25 is arranged near the well center 21, e.g. an iron roughneck machine and/or a mechanized power tong device.

(33) In this example, the drill floor 20 is arranged in a mobile manner on a base structure 30 of the rig so as to be movable between a collapsed or assembly position on the one hand and a raised or operative position relative to the base structure 30 on the other hand (as shown in the figures).

(34) The FIG. 1 illustrates that the base structure comprises a left-hand base member 31 and a right hand base member 32, each composed of two elongated parts 31a, 31b, 32a, 32b that are connected end-to-end.

(35) Between the drill floor 20 and each base member 31, 32, here parts 31a, 32a thereof, two legs 25a, 26a, b extend that are pivotally connected to both the drill floor and the base member 31, 32 to form a parallelogram. If desired more parallel legs can be provided between each base member and the drill floor.

(36) Each base member 31, 32 is further provided with a telescopic hydraulic cylinder 34, 35 that is connectable to the drill floor 20 for moving the drill floor 20 between the collapsed and raised position thereof. If desired another motorized drive, e.g. including a winch, may be provided for this purpose.

(37) FIG. 1 illustrates the presence of a locking beam 36 to lock the drill floor in its raised position.

(38) The figures illustrate that the base structure, here the members 31, 32, are provided with displacement feet 41, 41 allowing the rig 1, in erected state, to be displaced over the drill site, e.g. from one wellbore to an adjacent wellbore. An example thereof is explained in WO2013/109147 of the present applicant.

(39) The drill floor 20 in its raised position allows for the arrangement of a BOP and/or other wellbore related equipment underneath the drill floor.

(40) The mast, base structure, and/or drill floor of the drilling rig could also be embodied as described in for example WO2013/133698 or in WO2014/178712 of the present applicant.

(41) FIG. 1 also depicts the presence of a tubulars handling device 50 adapted to move tubulars between a vertical position aligned with the firing line through the well center 21 and a horizontal pick-up position. The depicted device is embodied as described in WO2014/133389 of the present applicant, which is incorporated by reference herein. In another embodiment, for example, the tubulars handling device 50 can be designed as described in WO2006/038790 of the present applicant.

(42) FIG. 1 also depicts the presence of a tubulars bin system 60, e.g. in an embodiment as disclosed in WO2013/109148 of the present applicant with bins 61, 62 for storage and transportation of drilling tubulars, e.g. drill pipe joints 3, as well as an arrangement of slide bars 64 that allow for motion of the tubulars between the bins 61, 62 and the tubulars handling device 50.

(43) The mast 10, here intermediate section 16 thereof, is provided with one or more fingerboard devices 71, 72 that are adapted to store drilling tubulars stands 4 assembled from multiple drilling tubulars 3, here three as the stands are so-called triples having a length of about 90 ft.

(44) As illustrated a left-hand fingerboard device 71 is mounted to the left-hand side 11a of the mast and a right-hand side fingerboard device 72 is mounted to the right-hand side 11c of the mast. Each of these fingerboard devices 71, 72 has fingers defining slots that extend parallel to the respective side of the mast and are open at the front side of the fingerboard device 71, 72.

(45) The lower ends of the store tubulars stands 4 may be supported on a non-depicted lower end support member for the stands.

(46) The rig 1 further comprises a top drive system 100 and a vertical motion drive that is adapted to cause vertical motion of the top drive system 100 relative to the drilling tower 10 in order to perform drilling and tripping operations.

(47) First the top drive system 100 will be discussed. The top drive system 100 comprises: a traveling carriage 110 that is vertically mobile along vertical rails 17, 18 of the drilling tower by means of the vertical motion drive, a top drive unit 120 that is supported by the carriage 110 and comprises a top drive motor 125 and a rotary torque output member 126, e.g. a rotary stem, that is adapted to be engageable with a top end of a drilling tubulars string extending in the firing line 23 through the well center 21 to impart torque to the drilling tubulars string in order to perform drilling operations, a tripping operation elevator 150 that is adapted to be engageable with a drilling tubulars string or drilling tubulars stand 4, e.g. with the top end thereof, in order to perform tripping operations.

(48) The figures illustrate that each of the front vertical posts 13a, d of the mast 10 is provided with a corresponding vertical rail 17, 18 that is static in its vertical position, so non-mobile relative to the tower 10.

(49) The carriage 110 is provided with rail followers 111 (see FIG. 18), e.g. rollers and/or glide members, so that the carriage is only vertically mobile up and down relative to the mast, at least over the height of the stands 4 to be handled.

(50) In general terms, as will be explained in more detail below, the top drive unit 120 and the tripping operation elevator 150 are each mobile relative to the traveling carriage 110. Furthermore the top drive system is provided with one or more actuators 140 that are adapted to cause the relative motion of the top drive unit 120 and of the tripping operation elevator 150 so as to provide: a drilling mode (see e.g. FIGS. 14a-d, 15-18), a tripping mode (see e.g. FIGS. 9a-d, 10-14).

(51) In the drilling mode the top drive unit 120 is in operative position with the rotary torque output member 126 being aligned with the firing line 23. At the same time the tripping operation elevator 150 is in a non-operative position remote from the firing line 23, here forward of the firing line 23.

(52) In the tripping mode the tripping operation elevator 150 is in operative position aligned with the firing line 23 and at the same time the top drive unit 120 is in a non-operative position, here closer to the rear wall 11b of the C-cross section mast than in the operative drilling mode (e.g. compare FIGS. 14 and 18).

(53) As illustrated the top drive system 100 is embodied such that—in the tripping mode—an unobstructed zone is present vertically above the tripping operation elevator 150 that allows the top drive system to be lowered along a drilling tubulars stand 4 in the firing line 23 above the drill floor 20, at least so that the top drive system is below the top end thereof, e.g. allowing lowering till near the drill floor. This will be explained in more detail later in conjunction with the fast tripping sequence depicted in FIGS. 20-25.

(54) The top drive system 100 is also embodied such that—in the tripping mode and with the top drive system lowered at least below the top end of said drilling tubulars stand (see e.g. FIGS. 22, 23, 24)—the drilling tubulars stand 4 is removable from the firing line 23, primarily in lateral direction, to place the drilling tubulars stand 4 in a fingerboard device 71, 72. This allows for a fast tripping process to be conducted.

(55) As illustrated the top drive system 100 here further comprises a drilling operation elevator 160, distinct from the tripping operation elevator 150, which elevator 160 is adapted to retain a drilling tubular or tubular stand 4 in vertical orientation below the rotary output member 126 of the top drive unit 120 in its operative position.

(56) The top drive unit 120 comprises a top drive frame 121 that supports the top drive motor 125, a gear arrangement 122, and the rotary output member 126 that is supported by a bearing.

(57) The top drive unit here further comprises a grabber 127 and a mud saver valve 129 as is known in the art.

(58) The frame 121 is supported on the traveling carriage 110 by a parallelogram mechanism comprising at each of the left-hand side and the right-hand side of the carriage and the frame one pair of upper and lower support arms 131, 132. These arms 131, 132 are each pivotally connected to the carriage and the top drive unit to form four parallel and horizontal pivot axes 131a, 131b,132a, 132b.

(59) The actuators 140, e.g. hydraulic cylinders, are mounted between the traveling carriage 110 and the frame 121. Here one hydraulic cylinder 140 is mounted at the left-hand side and one at the right-hand side of the carriage 110 and the frame 121.

(60) As will be understood suitable actuation of the actuators 140 causes the top drive unit 120 to be displaced relative to the carriage 110 between a position more inward in the mast 10 (closer to the rear wall 11b of the mast) and a more forward position wherein the rotary output member 126 is aligned with the firing line 23. As is preferred, even in said more forward position, a major portion of the top drive unit is still within the contour of the mast 10.

(61) The carriage comprises a structural frame with a left-hand carriage frame member 110a and a right-hand carriage frame member 110b interconnected by one or more transverse frame members 110c. These one or more transverse frame members extend rearward of the firing line 23 to provide the mentioned unobstructed zone allowing the lateral removal of the tubulars stand in forward direction.

(62) As illustrated it is envisaged, as is preferred, that the firing line 23 is encompassed in a vertical plane P that extends between the front posts 13a, d of the mast 10, possibly between the guide rails 17, 18 so as to reduce any torsional loads.

(63) The tripping operation elevator 150 is suspended by right-hand side and left-hand side links 151 or bails that are each connected at an upper end thereof from a respective pivotal elevator support arm 153 that is pivotally connected to the carriage 110 about a horizontal pivot axis 131a.

(64) As illustrated the elevator support arms 153 are each integrated with a respective support arm, here upper support arms 131 at the right-hand side and left-hand side of the carriage 110 so that each pair of an arm 153 and an arm 131 forms a one piece arms member that is pivotal about a horizontal axis 131a with the integrated arms 153 and 131 diverging.

(65) The integration of a pair of arms 131, 153 into a one piece integrated pivotal arms member is one manner to achieve that the top drive unit 120 and the tripping operation elevator 150 are mechanically linked so as to move in unison when operating the one or more actuators 140 in order to switch between the mentioned drilling mode and the mentioned tripping mode.

(66) As will be appreciated, by the basically permanent presence of the tripping elevator 150 in the top drive system 100 of the first aspect of the invention, even when not in use when in drilling mode, a fast and efficient switching can be made between the drilling mode and the tripping mode. There is no need to then install the tripping elevator 150 at the time of switching, which is advantageous in view of demands for crew members.

(67) In an embodiment one or more detent devices, e.g. remotely controllable, are provided to secure the top drive unit and/or the support for the tripping elevator relative to the traveling carriage 110 in the drilling mode and the tripping mode. For example one or more mobile detent members, e.g. pins, are provided on the carriage that engage in a corresponding hole in one or more of the support arms.

(68) In an embodiment a linkage member may be provided to force each lower support arm 132 to move in the same direction as the upper support arm 131 when starting to move from a position, here corresponding to the drilling mode, wherein both said upper and lower support arms 131, 132 are vertical. The same effect may also be brought about by another means to force said corresponding motion of the support arms starting from the vertical position. As explained a vertical position of both arms 131, 132 is advantageous in view of the vertical load path. It is, however, also possible that said arms 131, 132 are not completely vertical in said drilling mode.

(69) Of course, e.g. when different dimensions of tubulars to be handled would require a different tripping operation elevator, it is envisaged that the tripping operation elevator may be arranged in an exchangeable manner. For example, as discussed herein, the winch 270 on the racking device can then be used for lifting and handling the rather heavy elevator 150. In a preferred embodiment, as discussed herein, the elevator 150 has a body that is suited to all envisaged tubular diameters to be handled, e.g. just requiring the exchange or adjustment of one or more locking members for adaptation to a specific diameter.

(70) In order to avoid any sway of the tripping operation elevator 150 in the drilling mode the top drive system further comprises a stabilizer rod 155 for each link 151 or bail from which the tripping operation elevator 150 is suspended. The stabilizer rods 155 each have one end that is pivotally connected to the link 151 and another end that is pivotally connected to the carriage 110 so as to form a parallelogram mechanism in combination with the pivotal elevator support arm 153. The stabilizer rods 155 are fixed length in this design. In an alternative a hydraulic cylinder or other telescopic actuator can be provided as stabilizer rod between a link 151 and the carriage 110.

(71) The figures illustrate that the tripping operation elevator 150 comprises a C-shaped body in top view with a laterally open, e.g. to the front, vertical passage 156 through the elevator body that is dimensioned to allow unhindered passage of the elevator body along the drilling tubulars stand 4 in the firing line when the carriage 110 is lowered during tripping out, i.e. clearing any enlarged diameter portion(s) thereon formed by one or more connectors of the drilling tubulars stand.

(72) The figures further illustrate that this elevator 150 comprises one or more mobile, here two pivotal, locking members 157, here on opposite sides of the vertical passage, which in a clearance position thereof (see left-hand locking member in FIG. 10) allow for passage of the enlarged diameter portion(s) during descent of the carriage 110 in tripping and in a locked position (see e.g. FIG. 8) engage underneath a shoulder formed by such an enlarged diameter portion, e.g. connector, e.g. threaded connector, of the tubular in order to allow the tubular, more in particular the tubulars string, to be lifted.

(73) As can be seen e.g. in FIG. 19 two locking members 157 may be provided on the tripping operation elevator 150, each pivotal about a horizontal axis, e.g. each having a tubular facing end with a semi-circular recess adapted to the diameter of the tubular to be handled. As shown an actuator 158 may be provided for each locking member, e.g. allowing for remote control of the locking member.

(74) FIG. 19 illustrates that the tripping elevator is provided with a C-shaped horizontal cross section funnel 159 at its lower end facilitating the sliding of the elevator along the tubulars stand 4 during descent of the carriage 110.

(75) It is illustrated that the drilling operation elevator 160 is equally suspended from links or bails 161 that are here pivotally suspended from the top drive unit 120.

(76) As is known in the field the drilling operation elevator 160 comprises an annular elevator body 162 that can be opened to allow introduction of a tubular in the elevator and then closed to form a closed annular body around the tubular, e.g. an actuator being provided for remote controlled opening and closing of the drilling elevator body. As is known in the field the closed annular elevator body may engage underneath a shoulder formed by an enlarged diameter portion of a tubular, e.g. a connector, e.g. a threaded connector at the end of the tubular.

(77) A motorized tilt mechanism 163 is provided to cause controlled tilting of the links 161 as is known in the art.

(78) In order to move the traveling carriage 110 up and down along the mast 10, the mast crowns section is provided with a crown block assembly 210 with a left-hand set 211 of sheaves and a right-hand set 212 of sheave, which sets are spaced apart from one another seen from the front of the mast so that an opening that is open at the front is present between the two sets, with the firing line 23 passing through this opening.

(79) The sheaves of the sets 211, 212 have horizontal axes generally parallel and in or close to the plane P, here at a small angle. An equalizing sheave 213 of the crown block is provided more rearward, at the rear of the mentioned opening between the sets 211, 212.

(80) The traveling carriage 110 is provided with a left-hand set 215 of sheaves and a right-hand set 216 of sheave with sheaves, which sets sheaves are spaced apart from one another seen from the front of the mast so that an opening that is open at the front is present between the two sets, with the firing line 23 passing through this opening.

(81) As illustrate the set 215 is mounted at the top of frame member 110a and the set 216 at the top of frame member 110b.

(82) The sheaves on the travelling carriage 110 are also rotatable about a horizontal sheave axis.

(83) The rig 1 is provided with one or more, here two, drawwork winches 217, 218; one on each side of the base structure. Both winches 217, 218 here connect to a single drawwork cable 219 which cable passes over the mentioned sheaves in two multiple fall groups along the right-hand side and left-hand side of the mast, here along the inside of the respective front post 13a, d, so as to suspend the traveling carriage 110 from the crown block.

(84) As illustrated it is envisaged that one or more of the sheaves 215, 216 associated with the traveling carriage 110 may each be integrated in a respective detachable sheave block that is individually connectable and detachable, e.g. by remote control from an operator cabin, to the carriage 110 and which, when detached, may be locked (and unlocked), e.g. by remote control from an operator cabin, in an elevated position below the respective set of sheaves of the crown block. This allows to vary the active number of falls from which the carriage is suspended, e.g. allow for faster operation in situations wherein the load requirements are limited and allow for an increased number of active falls when high loads are to be handled.

(85) As explained a left-hand fingerboard device 71 is mounted to the left-hand side 11a of the mast and a right-hand side fingerboard device 72 is mounted to the right-hand side 11c of the mast 10. As shown each fingerboard device has fingers defining slots that extend parallel to the respective side of the mast and are open at the front side of the fingerboard device to allow for lateral introduction and removal of a tubulars stand from the fingerboard.

(86) As illustrated the drilling rig comprises a tubulars racking device 250 comprising one or more mobile tubulars gripper assemblies adapted to grip a tubular or tubulars stand 4 and move the tubular or tubulars stand between the fingerboard device 71, 72 and the firing line 23.

(87) The tubulars racking device 250 comprises a structural frame supported by the mast 10, mainly at the front side thereof, at an elevated position thereon relative to the drill floor 20.

(88) It is illustrated, see e.g. FIG. 7, that the mast 10 is provided with one or more cantilevers 266, 267 at a height above the structural frame of the racking device 250, here said cantilevers 266 being secured to the front posts 13, d and extending in forward direction.

(89) Between each cantilever 266, 267 and the structural frame of the racking device one or more suspension cables or rods 268, 269 extend so as to provide additional vertical support for the structural frame.

(90) As can be seen e.g. in FIGS. 5a, b this structural frame comprises one or more horizontal rails 254, 255 extending across the front side of the mast 10 and across the front sides of the fingerboard devices 71, 72.

(91) The racking device 250 comprising a mobile tubulars gripper assembly 251 guided by said one or more rails 254, 255 and provided with one or more grippers 252, 253 and adapted to grip a tubular stand 4 and move the tubulars stand between the fingerboard devices 71, 72 and the firing line 23. As will be appreciated that the racking device is embodied to allow for passage of the top drive system 100 in its drilling mode and in its tripping mode.

(92) In this example the assembly 251 comprises a vertical carrier beam 256 which is supported by the one or more rails 254, 255 to allow travel in X-direction over said one or more rails 254, 255 and a vertical gripper beam 257 that is connected to the carrier beam 256 by parallelogram arms 258, 259 to allow travel of the grippers 252, 253 in Y-direction, here parallel to the slots in the fingerboards 71, 72.

(93) The gripper beam 257 carries the one or more grippers 252, 253, e.g. one gripper 252 at a fixed location and one being adjustable in vertical direction or both being adjustable in vertical direction relative to the gripper beam, e.g. in view of a controlled vertical stabbing motion by means of a vertical stabbing actuator 260 between the one or more grippers 252, 253 and the beam 257.

(94) As is preferred the racking device 250 is also embodied to allow for vertical motion, in Z-direction, of the gripper beam 257. Here the vertical carrier beam 256 is provided with travellers 256a, 256b that vertically travel over the beam 256, which each traveller 256a, 256b having a hinge connected to a respective parallelogram arm 258, 259. A vertical motion actuator for the one or more travellers 256a, 256b is provided, here a vertically mounted hydraulic cylinder 256c between the lowermost traveller 256a and the carrier beam 256. This can be best seen in FIG. 5b, where the reference numeral is linked to the extended piston rod of the cylinder.

(95) The FIGS. 5a,b also illustrate that the mobile tubulars gripper assembly 251 of the tubulars racking device is provided with an auxiliary winch 270 and a winch driven cable 271, here passing over a sheave 272 mounted on the gripper beam 257, e.g. at the lower end thereof.

(96) As the beam 257 is movable in both X and Y directions in a horizontal plane, the sheave 272 and thus the cable 271 is also movable in these X and Y directions. It is envisaged that the mobile tubulars gripper assembly 251 is positionable at least in a position such that the winch driven cable 272 is aligned above the well center 21, so in the firing line 23, and can be lowered to the well center 21 on the drill floor 20 to perform lifting operations above or near the well center using the auxiliary winch 270 on the tubulars racking device. For example a hook is present at the end of cable 271. For example the winch 270 can be used for lifting the slip device 22, e.g. when placed in a corresponding recess in the drill floor.

(97) FIG. 7 illustrates that the tower, here the U-shaped horizontal cross section mast 10, is provided at the top thereof with an auxiliary crane 300 having a base 301 secured to the tower and a crane boom 302 connected via a vertical axis slew bearing 303 to the base 301 allowing to slew the boom, e.g. about a full revolution.

(98) The auxiliary crane 300 comprises a winch 305 and a winch driven cable 306 for hoisting of objects. The auxiliary crane is embodied such that the winch driven cable 306 can be passed vertically along the firing line 23 down to the well center 21 in the tripping mode of the top drive system 110 so as to allow for use of the auxiliary crane 300 for lifting operations at or near, or towards and away from, the well center 21.

(99) Here it is shown that the auxiliary crane 300 is a jib or cantilever crane, wherein the boom 302 extends permanent in horizontal direction and wherein a trolley 308 is displaceable along the boom, with the trolley being provided with a sheave. The trolley 308 is at least positionable so that the winch driven cable 306 passing over the sheave is aligned with the firing line, and a position remote from said firing line position. The trolley could also support a winch with a winch driven cable.

(100) With reference to the illustrations in FIGS. 20-25 now a method for use of the drilling rig of FIG. 1 will be discussed, in particular a method for tripping out a drilling tubulars string from a wellbore.

(101) In FIG. 20 a situation is depicted wherein a drilling tubulars string 7 is suspended in the wellbore by means of the slip device 22. A top end portion of the string 7 sticks out above the slip device, which top end (as common) is provided with an enlarged diameter connector.

(102) The top drive system 100 is in the described tripping mode and the traveling carriage 110 has been lowered to an initial engagement level wherein the tripping operation elevator 150 is connected with the top end of the suspended string 7.

(103) As illustrated in FIG. 21, for tripping out, the slip device 22 has released the string 7 and the carriage 110 has been lifted, so as to pull up a tubulars stand 4 above the well center 21 by means of the elevator 150. In this example a double length stand 4 is pulled, but this could also be a triple stand 4.

(104) The slip device 22 is now operated to reengage on the string 7 so that the string 7, still including the connected stand 4, is vertically retained.

(105) Now the carriage 110 is lowered back towards the initial engagement level. As the stand 4 still is in the firing line 23 the tripping operation elevator 150 slides down along the stand 4. During this lowering step the device 25 is operated to break up the connection between the stand 4 and the rest of the drill string, which includes advancing the device 25 from a parking position to a well center position as is shown in FIGS. 22, 23.

(106) Once the carriage has been lowered enough it becomes possible to engage one or more, e.g. both of the grippers of the racking device 250 (highly schematically shown in FIG. 24) with the stand 4, e.g. the grippers 251, 252 already encircling and/or gripping the stand 4 prior to the actual disconnection. The gripped stand 4 is then raised to complete the disconnection and allow for the racking device to move the stand laterally, e.g. in forward direction, out of the elevator 150 and to store the stand in a fingerboard 71, 72 as schematically depicted in FIG. 25. This may involve actuation of locking members 157 to bring them in the clearance position.

(107) The descent of the carriage 110 is preferably done without pausing, and finally the elevator—with the stand 4 being removed from the firing line—reaches the top end of the suspended string 7 and engages therewith, e.g. by opening and then closing the locking members 157, so as to allow for the lifting of a next stand above the well center 21.

(108) As will be appreciated the operations of the used devices may all be coordinated by one suitably programmed computerized controller, so that the entire tripping process or at least a significant part of the string tripping, may be done in automated manner, e.g. under supervision of one or more operators in an operator cabin, e.g. with a view on the front side of the mast.

(109) It will be appreciated that tripping out is done fast as at least one of the following steps is performed in time overlap with the lowering of the carriage 110: disconnecting the lifted tubulars stand 4 from the suspended drill string by means of said tubulars connection makeup and breaking device 25 near the well center, removing the disconnected tubulars stand 4 from the firing line, primarily in lateral direction, here by means of the racking device 250, placing the drilling tubulars stand in said fingerboard device, here by means of the racking device 250.

(110) For example as soon as the elevator 25 has been lowered along the stand to a level below the grippers of the racking device, the grippers can be made to grip the stand 4 and the device 25 can be operated to disconnect the stand 4 by breaking the lower connection thereof. As soon as the disconnect is brought about, preferably with the elevator 150 still descending, the racking device is operated to move the stand away from the firing line 23. The latter may involve remote control operation of the one or more locking devices 157 to allow the stand to be moved laterally out of the still descending elevator. The racking device 250 can then continue to place the stand 4 in a fingerboard 71, 72 and the elevator 150 can be lowered over the top end of the next stand to be pulled out.

(111) It will also be appreciated that—in the drilling mode—the top drive unit 120 is operable in its normal manner, with the rotary output member aligned with the firing line 23 and with the elevator 150 moved into a non-operative position remote from the firing line.

(112) Preferably all equipment involved in the tripping operation as discussed is connected to a central computerized control unit that is programmed to perform the tripping operation, at least of a major part of the drilling tubulars string 7, fully automated. It is envisaged that in such fully automated tripping sequence one or more operators in an operator cabin merely serve to supervise the process and respond in case of anomalies. In a semi-automated sequence some commands may be given via one or more input devices by the one or more operators, these commands starting parts of the sequence.

(113) The skilled person will appreciate that the described drilling rig also allows for efficient and fast tripping in, which is basically done in reverse order of tripping out.