United States Patent: (10) Patent No .: US 9, 988, 807 B2

|HAO WATATU NA MARIA DELO NAKUWAM T U US009988807B2
(12) United States Patent ( 10) Patent No.: US 9,988,807 B2

Konduc et al. (45) Date of Patent : Jun . 5 , 2018
(54 ) DRILLING RIG WITH SELF -ELEVATING (56 ) References Cited
DRILL FLOOR U . S . PATENT DOCUMENTS
(71 ) Applicant: National Oilwell Varco , L . P., Houston , 295, 172 A 3 /1884 Hill
TX (US) 1,557 ,070 A 10 / 1925 Logue
2 , 420 , 803 A 5 / 1947 Tobin
(72 ) Inventors: Kameron Wayne Konduc, Edmonton 2 ,657,017 A 10 /1953 Curtis
(CA ); Elijah Jakobsohn , Spring , TX (Continued )
(US); Brian Daniel Winter , Cypress ,
TX (US ) FOREIGN PATENT DOCUMENTS
CN 101476312 7 /2009
( 73 ) Assignee : National Oilwell Varco, L . P., Houston ,
@ CN 102536267 7 /2012
TX (US ) (Continued )
( * ) Notice : Subject to any disclaimer, the term of this OTHER PUBLICATIONS
patent is extended or adjusted under 35
U . S .C . 154 (b ) by 0 days. days . Blue Calypso, LLC v. Groupon , Inc. ( CAFC , Mar. 1, 2016 ) (46
pages ).
(21) Appl. No.: 15 /051,800 ( Continued )
(22 ) Filed : Feb . 24 , 2016 Primary Examiner — Gisele D Ford
(65) Prior Publication Data (57 ) ABSTRACT
The present disclosure , in one or more embodiments, relates
US 2017 /0241126 A1 Aug . 24 , 2017 to a drilling rig with a self- elevating drill floor. The drilling
rig may have one or more jacking systems that may operate
(51) Int. CI. to raise the drill floor. The one or more jacking systems may
E04B 1/ 35 ( 2006 . 01) raise the drill floor to a height sufficient to accommodate a
E21B 15 /00 ( 2006 .01) substructure such as a substructure box . A substructure box
E21B 41/00 ( 2006 .01) may be placed , and the one or more jacking systems may
B66F 3 /46 ( 2006 .01) lower the drill floor onto the substructure box . Substructure
(52) U .S . CI. boxes may be placed beneath the drill floor, using the one or
CPC .............. E04B 1/3522 (2013 .01 ); B66F 3/46 more jacking systems, until a desired drill floor height is
(2013.01 ); E04B 1/ 3511 ( 2013 .01) ; E21B reached . In some embodiments, the one or more jacking
15 /00 (2013 .01); E21B 41/00 (2013.01 ) systems may additionally operate to move the drilling rig,
(58 ) Field of Classification Search for example between adjacent wells on a pad drilling site.
CPC .......... E21B 15 /00 ; E21B 7/023; E21B 15/04 ; The jacking systems may operate the move the drilling rig
E21B 15 /003 using walking feet or another movement mechanism .
See application file for complete search history . 19 Claims, 46 Drawing Sheets
- 110
D
120
OS
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US 9,988 ,807 B2
Page 2
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Page 3
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U . S . Patent Jun. 5 , 2018 Sheet 46 of 46 | US 9, 988, 807 B2
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US 9, 988, 807 B2
DRILLING RIG WITH SELF - ELEVATING provide a basic understanding of such embodiments . This
DRILL FLOOR summary is not an extensive overview of all contemplated
embodiments , and is intended to neither identify key or
FIELD OF THE INVENTION critical elements of all embodiments , nor delineate the scope
The present application is generally directed to drilling rig 5 of The
any or all embodiments.
present disclosure, in one or more embodiments ,
assemblies. Particularly , the present application relates to relates to a method for elevating a drill floor of a drilling rig .
elevated platforms, tables, decks, floors , or other elevated The method may include: (a ) using at least one jacking
surfaces and constructing , installing, erecting , or building system
such surfaces . More particularly , the present application ,10 drilling, rig
raising the drill floor such that the dead load of the
is transferred to the at least one jacking system ;
relates to a drilling rig having a self-elevating drill floor. (b ) inserting a layer of substructure boxes beneath the drill
BACKGROUND OF THE INVENTION floor; ( C ) using the at least one jacking system , lowering the
drill floor onto the layer of substructure boxes , such that the
The background description provided herein is for the dead load of the drilling rig is transferred from the at least
purpose of generally presenting the context of the disclo - 15 one jacking system to the layer of substructure boxes ; and
sure . Work of the presently named inventors, to the extent it (d ) coupling the layer of substructure boxes to the drill floor.
is described in this background section , as well as aspects of In some embodiments , the method may include repeating
the description that may not otherwise qualify as prior art at steps ( a ) through ( d ) until a desired drill floor height is
the time of filing, are neither expressly nor impliedly admit - reached . In some embodiments , the jacking system may be
ted as prior art against the present disclosure . 20 a telescoping jacking system . Further , in some embodi
In many land -based oil and gas drilling operations, drill - ments, the jacking system may have a skid foot movement
ing rigs may be delivered to an oilfield drilling site by mechanism . The skid footmovementmechanism may allow
transporting various components of the drilling rig over the drilling rig to be moved in each of a latitudinal and a
roads, highways, and /or railroads . The various drilling rig longitudinal direction . In some embodiments , inserting a
components may be transported to a drilling site on one or 25 layer of substructure boxes may include arranging a sub
more truck /trailer combinations, rail cars , or other modes of structure box around a jacking system , such that the jacking
transportation , the number ofwhich may depend on the size , system is at least partially housed within the substructure
weight, and complexity of the rig . Once at the drilling site , box . In some embodiments , four jacking systems may be
the drilling rig components may be assembled , and the used to raise and lower the drill floor, and inserting a layer
drilling rig assembly may be raised to an operating position 30 of substructure boxes may include arranging the layer of
so as to perform drilling operations. After the completion of substructure boxes into at least one tower configuration . In
drilling operations , the drilling rig may be lowered , disas - some embodiments, the drill floor may include a first layer
sembled , loaded back onto truck / trailer combinations, rail of substructure boxes, and raising the drill floor may include
cars, or other modes of transportation , and transported to a coupling the jacking system to the first layer of substructure
different oilfield drilling site for new drilling operations. 35 boxes and raising the drill floor and first layer of substructure
Accordingly, the ease with which the various drilling rig boxes a distance off the ground surface. In some embodi
components can be transported , assembled and disas - ments, the at least one substructure box may include a first
sembled , and raised and lowered can be a substantial factor layer of substructure boxes, and the method may further
in the drilling rig design , as well as the rig 's overall include: ( e ) using the at least one jacking system , raising the
operational capabilities and cost effectiveness . 40 drill floor and the first layer of substructure boxes such that
Moreover, in particular parts of the world , access to the dead load of the drilling rig is transferred to the at least
cranes or other equipment for assembling and disassembling one jacking system ; ( f) inserting a second layer of substruc
operations may be relatively limited and , in particular, the ture boxes beneath the first layer of substructure boxes , the
availability of large, high lifting cranes may be limited second layer comprising at least one substructure box ; ( g )
Where a large drilling rig with a high floor height is desired 45 using the at least one jacking system , lowering the drill floor
to provide for deep drill depths and high drilling capacities , and the first layer of substructure boxes onto the second
the absence of large crane availability may create difficulties layer of substructure boxes, such that the dead load of the
or impasses in assembly and disassembly of drilling rigs . drilling rig is transferred from the at least one jacking system
In someapplications , drilling operations at a given oilfield to the second layer of substructure boxes; (h ) and coupling
drilling site may involve drilling a plurality of relatively 50 the second layer of substructure boxes. Additionally , the
closely spaced wellbores, sometimes referred to as “ pad ” method may include repeating steps (e ) through (h ) until a
drilling. In pad drilling, the distance between adjacent desired drill floor height is reached .
wellbores may be as little as 20 -30 feet or less in some Additionally , the present disclosure, in one or more
applications . The plurality of wellbores are often arranged in embodiments , relates to a method for elevating a drill floor
a two -dimensional grid pattern , such that rows and columns 55 of a drilling rig , wherein the drill floor is supported by at
of wellbores may be disposed along lines running substan - least one substructure column. The method may include ( a )
tially parallel to an x -axis and a y - axis, respectively. In such using a jacking system , raising the drill floor and the
pad drilling applications, after drilling has been completed at substructure column a distance off of the ground surface ; (b )
one wellbore , the drilling rig may be moved to an adjacent inserting a substructure box beneath the column, such that
wellbore . Often , after drilling operations have been com - 60 the substructure box is arranged about the jacking system ;
pleted at the pad site , the drilling rig may be relocated to a (c ) using the jacking system , lowering the drill floor and
different drill site , which may also be a pad site . substructure column onto the substructure box ; ( d ) coupling
the substructure box to the column ; and ( e ) repeating steps
BRIEF SUMMARY OF THE INVENTION ( a ) through ( d ) until a desired drill floor height is achieved .
65 In some embodiments , the substructure box may be a
The following presents a simplified summary of one or C -shaped substructure box . Raising the drill floor may
more embodiments of the present disclosure in order to include coupling the jacking system to the substructure
US 9 ,988,807 B2
column , and raising the drill floor and substructure column FIG . 7A is a side view of a support bar and swing win in
a distance off of the ground surface . In some embodiments , a lifting position , according to one or more embodiments .
the jacking system may be a telescoping jacking system . The FIG . 7B is a side view of a support bar and swing arm in
jacking system may additionally or alternatively include a a clearance position , according to one or more embodiments .
skid foot movement mechanism . The skid foot movement5 FIG . 7C is a side view of a support bar and swing arm in
mechanism may allow the drilling rig to be moved in each a coupling position , according to one or more embodiments .
of a longitudinal and a latitudinal direction . FIG . 8A is a side view of a jacking system in a lowered
Additionally , the present disclosure , in one or more position , according to one or more embodiments.
embodiments, relates to a drilling rig with a self-elevating FIG . 8B is a side view of a jacking system in a raised
drill floor. The drilling rig may include a mast , a drill floor position , according to one or more embodiments.
supporting the mast, a substructure comprising one or more FIG . 9 is a top down view of a jacking system according
columns of substructure boxes , and a jacking system com - to one or more embodiments .
prising a telescoping cylinder and a skid movement mecha - FIG . 10A is a side view of a jacking system arranged in
nism . The jacking system may be configured to use the 16 a substructure box with support bars in a lifting position ,
telescoping cylinder to raise the drill floor such that one or according to one or more embodiments .
more substructure boxes may be inserted beneath the drill FIG . 10B is a top down view of the jacking system and
floor, and use the skid movement mechanism to skid the substructure box of FIG . 10A .
drilling rig in each of a latitudinal and longitudinal direc - FIG . 11A is a side view of a jacking system arranged in
tions . In some embodiments, the one or more substructure 20 a substructure box with support bars in a clearance position ,
boxes may be a C -shaped substructure box . Further, the according to one or more embodiments.
jacking system may be configured to raise the drill floor by FIG . 11B is a top down view of the jacking system and
coupling to the substructure and raising the drill floor and substructure box of FIG . 11A .
substructure a distance off of the ground surface . FIG . 12A is a top down view of a jacking system arranged
While multiple embodiments are disclosed, still other 25 in a substructure box with support bars in a lifting position ,
embodiments of the present disclosure will become apparent according to one or more embodiments .
to those skilled in the art from the following detailed FIG . 12B is a top down view of a jacking system arranged
description , which shows and describes illustrative embodi- in a substructure box with support bars in a clearance
ments of the invention . As will be realized , the various position , according to one or more embodiments.
embodiments of the present disclosure are capable ofmodi- 30 FIG . 13A is a side view of a vertical stack of two
fications in various obvious aspects , all without departing substructure boxes raised by a jacking system such that a
from the spirit and scope of the present disclosure . Accord third substructure box may be positioned beneath the stack ,
ingly , the drawings and detailed description are to be according to one or more embodiments .
regarded as illustrative in nature and not restrictive . FIG . 13B is a side view of an opposing side of the vertical
35
BRIEF DESCRIPTION OF THE DRAWINGS stack of boxes and jacking system of FIG . 13A , according to
one or more embodiments .
While the specification concludes with claims particularly FIG . 14 is a side view of a drill floor, a first layer of a
pointing out and distinctly claiming the subject matter that substructure, and a pre -erected mast of a drilling rig , accord
is regarded as forming the various embodiments of the 40 ing to one or more embodiments .
present disclosure, it is believed that the invention will beFIG . 15 is a side view of the elements of FIG . 14 with
better understood from the following description taken in lifting cylinders extended , according to one or more embodi
conjunction with the accompanying Figures , in which : ments .
FIG . 1 is a side view of a drilling rig , according to one or FIG . 16 is a side view of the elements of FIG . 15 , with the
more embodiments . 45 mast pinned to mast shoes, according to one or more
FIG . 2A is a side view of a substructure box with support embodiments .
bars in a lifting position , according to one or more embodi FIG . 17 is a side view of the elements of FIG . 16 , with the
ments . lifting cylinder in a mast -erecting position , according to one
FIG . 2B is a top down view of the substructure box of or more embodiments .
FIG . 2A . 50 FIG . 18 is a side view of the elements of FIG . 17 , with the
FIG . 3A is a side view of a substructure box with support lifting cylinders extended and the mast in an erected posi
bars in a clearance position , according to one or more tion , according to one or more embodiments .
embodiments. FIG . 19 is a side view of the elements of FIG . 18 , with the
FIG . 3B is a top down view of the substructure box of lifting cylinders detached , according to one or more embodi
FIG . 3A . 55 ments .
FIG . 4A is a left side view of a substructure box according FIG . 20A is a side view of jacking systems and a first layer
to one or more embodiments . of substructure boxes, according to one or more embodi
FIG . 4B is front side view of the substructure box of FIG . ments .
4A , according to one or more embodiments . FIG . 20B is a side view of the elements of FIG . 20A , with
FIG . 4C is a right side view of the substructure box of 60 the jacking systems positioned within the substructure
FIG . 4A , according to one or more embodiments. boxes, according to one or more embodiments .
FIG . 5 is a side view of a vertical stack of substructure FIG . 20C is a side view of the elements of FIG . 20B , with
boxes, according to one or more embodiments . the jacking systems coupled to the support bars, according
FIG . 6 is a side view of the vertical stack of substructure to one or more embodiments .
boxes of FIG . 5 , with the first, second , and third layer of 65 FIG . 20D is a side view of the elements ofFIG . 20C , with
boxes coupled together , according to one or more embodi- the jacking systems extended , according to one or more
ments . embodiments .
US 9,988,807 B2
FIG . 20E is a side view of the elements of 20D , with an FIG . 32 is a side view of the drilling rig of FIG . 31, with
added second layer of substructure boxes , according to one an added fourth layer of substructure boxes, according to
or more embodiments . one or more embodiments.
FIG . 20F is a side view of the elements of FIG . 20E , with FIGS. 33A - Q each illustrate the steps of FIGS. 20A -F ,
the first layer of substructureboxes positioned on the second 5 24A -E , and 28A -E respectively.
layer of substructure boxes , according to one or more FIG . 34 is a side view of first, second, third , and fourth
embodiments . layers of substructure boxes with jacking systems secured to
FIG . 21 is a side view of the drilling rig of FIG . 19 , with the fourth layer of substructure boxes, according to one or
the jacking systems extended , according to one or more 10 more embodiments .
FIG . 35A is a side view of a vertical stack of substructure
embodiments .
FIG . 22 is a side view of the drilling rig of FIG . 21, with boxes , according to one or more embodiments .
FIG . 35B is an opposing side view of the vertical stack of
an added second layer of substructure boxes, according to substructure boxes of FIG . 35A , according to one or more
one or more embodiments . embodiments .
FIG . 23 is a side view of the drilling rig of FIG . 22 with
the jacking systems lowered , according to one or more DETAILED DESCRIPTION
embodiments .
FIG . 24A is a side view of jacking systems and a first layer The present disclosure , in one or more embodiments,
and second layers of substructure boxes , according to one or relates to a drilling rig with a self -elevating drill floor. The
more embodiments . 20 drilling rig may have one or more jacking systems that may
FIG . 24B is a side view of the elements of FIG . 24A , with operate to raise the drill floor. The one or more jacking
the support bars of the second layer in a lifting position , systems may raise the drill floor to a height sufficient to
according to one or more embodiments . accommodate a substructure such as a substructure box . A
FIG . 24C is a side view of the elements of FIG . 24B , with substructure box may be placed , and the one or more jacking
the jacking systems extended , according to one or more 25 systems may lower the drill floor onto the substructure box .
embodiments . Substructure boxes may be placed beneath the drill floor ,
FIG . 24D is a side view of the elements of FIG . 24C , with using the one or more jacking systems, until a desired drill
an added third layer of substructure boxes, according to one floor height is reached .
or more embodiments . A self- elevating drill floor of the present disclosure may
FIG . 24E is a side view of the elements of FIG . 24D , with 30 allow a drilling rig to be erected or partially erected at a
the second layer of substructure boxes positioned on the drilling site , for example , using relatively low capacity
third layer of substructure boxes, according to one or more trucks, bull dozers, cranes , such as rubber tire cranes , and /or
embodiments . other relatively low capacity vehicles . In this way, the use of
FIG . 25 is a side view of the drilling rig of FIG . 23, with high lift cranes to erect the drilling rig , or at least a portion
the jacking systems extended , according to one or more 35 of the drilling rig , may be avoided . In some embodiments ,
embodiments . the one ormore jacking systemsmay additionally operate to
FIG . 26 is a side view of the drilling rig of FIG . 25 , with move the drilling rig , for example between adjacent wells on
an added third layer of substructure boxes, according to one a pad drilling site . The jacking systems may operate the
or more embodiments . move the drilling rig using walking feet or another move
FIG . 27 is a side view of the drilling rig of FIG . 26 , with 40 ment mechanism . This may allow the drilling rig to be
the jacking systems lowered , according to one or more moved , such as between adjacent wells on a pad drilling site ,
embodiments . without the need for disassembly of the rig between wells .
FIG . 28A is a side view of jacking systems and a first drilling rig 100 with a mast 110 , a drill floor 120, and
layer , second layer , and third layer of substructure boxes , a substructure 130 is shown in FIG . 1 . The mast 110 and drill
according to one or more embodiments . 45 floor 120 may be supported , at least in part , by the substruc
FIG . 28B is a side view of the elements of FIG . 28A , with ture 130 . The substructure 130 may have one or more
the support bars of the third layer in a lifting position , substructure boxes 140 . Substructure boxes 140 may be
according to one or more embodiments . vertically stacked on one another, as shown in FIG . 1 . The
FIG . 28C is a side view of the elements of FIG . 28B , with substructure boxes 140 may be arranged so as to distribute
the jacking systems extended , according to one or more 50 the weight of the rig 100 . For example , the rig 100 may be
embodiments . supported by a vertical stack of substructure boxes 140 at
FIG . 28D is a side view of the elements of FIG . 28C , with each corner of the drill floor 120 . In other embodiments ,
an added fourth layer of substructure boxes , according to more or fewer stacks of substructure boxes 140 at different
one or more embodiments . locations may support the drilling rig 100. The drilling rig
FIG . 28E is a side view of the elements of FIG . 28D ,with 55 100 may have one or more jacking systems 150 . For
the third layer of the substructure boxes positioned on the example , a jacking system 150 may be housed within each
fourth layer of substructure boxes, according to one or more vertical stack of substructure boxes 140. Each jacking sys
embodiments . tem 150 may operate to raise the drilling rig 100 vertically,
FIG . 29 is a side view of a jacking system and a first layer, and in some cases off of the ground . The jacking systems
second layer, third layer, and fourth layer of substructure 60 150 may be used to raise the rig 100 so as to add a
boxes , according to one or more embodiments . substructure box 140 to each vertical stack , or to remove a
FIG . 30 is a side view of the elements of FIG . 29 with thesubstructure box from each stack . Additionally or alterna
first second and third layers of substructure boxes coupled tively , the jacking systems 150 may operate as walking feet
together, according to one or more embodiments . to facilitate horizontal movement of the rig 100 along the
FIG . 31 is a side view of the drilling rig of FIG . 27, with 65 ground surface .
the jacking systems extended , according to one or more Each substructure box 140 may have generally any suit
embodiments . able size and shape . In some embodiments, a substructure
US 9 ,988,807 B2
box 140 may have a rectangular shape, as shown in FIGS. member 142u having first and second portions separated by
2 - 3 . In some embodiments, the substructure box 140 may a gap . Each portion of the upper horizontal member 142u
have a height , depth , and width of approximately 6 feet. In may extend from a perpendicular upper horizontal member
other embodiments, a substructure box 140 may have any on a connecting side face to an intermediate member 164 in
suitable height, depth , and width , or other dimensions . In 5 some embodiments . FIGS . 4A , 4B , and 4C illustrate the
some embodiments , substructure boxes 140 of differing substructure box 140 from three different side views, respec
shapes and / or sizes may be used . A substructure box 140 is tively . While FIGS . 4B and 4C illustrate first and second
shown from a side view in FIGS. 2A and 3A . Each sub - vertical faces having horizontal 142, vertical 144, and cross
structure box 140 may include a plurality of horizontal 142 , members 146 , FIG . 4A shows a third vertical side face
vertical 144 , and cross 146 members . For example , in some 10 without cross members or a lower horizontal member 142u .
embodiments, a substructure box 140 may have four upper In this way, it may be appreciated that the substructure box
horizontal members 142u defining a face , such as an upper 140 may have a squared C -shape defined by the horizontal
face of the box , and four lower horizontal members 142 142 and cross 146 members of three vertical side faces and
defining an opposing face , such as a lower face of the box . an open fourth vertical side face .
From the side views of FIGS. 2A and 3A , one horizontal 15 As shown in FIG . 2A , a substructure box 140 may have
member 142 at each of the upper and lower faces is shown . one or more support bars 160 coupled to the substructure
Upper and lower horizontalmembers may have wide flange box . A support bar 160 may be generally configured for
shapes , as shown in FIGS. 2A and 3A , tube shapes , angle providing a support or a lift point for engagement by a
shapes, channel shapes, or any other structural steel shape or jacking system 150 to raise or lower the box 140 . A support
design . A substructure box 140 may additionally, in some 20 bar 160 may be positioned at or near one surface of the
embodiments, have a plurality of vertical members 144 substructure box 140 , such as the upper end defined by the
between the upper and lower faces defined by the horizontal four upper horizontal members 142u , in some embodiments .
members 142 . For example , a substructure box 140 may As shown in FIG . 2B , a support bar 160 may be positioned
have a vertical member 144 connecting each of four oppos generally parallel to two upper horizontal members 142u
ing corners of the upper and lower faces . From the side 25 and perpendicular to two upper horizontal members . A
views of FIGS. 2A and 3A , two such vertical members 144 support bar 160 may have any suitable length . In some
are shown. Verticalmembers may have wide flange shapes, embodiments , a supportbar 160 may span the depth or width
tube shapes, angle shapes, channel shapes , or any other of the substructure box 140, connecting to the box at each of
structural steel shape or design . Additionally , in some two horizontal members 142 , for example . In other embodi
embodiments, a substructure box 140 may have at least two 30 ments , a support bar 160 may span less than the full depth
cross members 146 on one or more faces of the rectangular or width of the substructure box 140 , as shown in FIG . 2B .
box . From the side views of FIGS. 2A and 3A , two cross A support bar 160 may have any suitable cross sectional
members are shown. Cross members may have wide flange shape. For example , in some embodiments, a support bar
shapes, tube shapes, angle shapes , channel shapes, or any 160 may have a round , rectangular, or other cross sectional
other structural steel shape or design . The horizontal 142 , 35 shape. Further, a support bar 160 may have any suitable
vertical 144 , and cross 146 members may generally define a cross sectional size . Generally , the size and shape of the
hollow space within the substructure box 140 . In other cross section of the support bar 160 may be configured to
embodiments , a substructure box 140 may have any suitable operate in conjunction with a jacking system 150 , as dis
number of horizontal 142, vertical 144 , and cross 146 cussed more fully below , where the support bar is shaped for
members. 40 seating within a saddle of the jacking system . A support bar
A substructure box 140 , including horizontal 142 , vertical 160 may be a steel, aluminum , wood , plastic , or other
144, and cross 146 members , may be composed of any material bar.
suitable material. In some embodiments, a substructure box Where a support bar 160 spans less than the full width or
may be composed of steel, aluminum , or any suitable metal depth of the substructure box 140, the support bar may be
or metal composite . In other embodiments , a substructure 45 coupled to a horizontalmember 142 at or near one end of the
box 140 may be composed of wood , plastic , concrete , or any bar, and to an intermediate member 164 at or near an
other suitable material. In some embodiments, some of the opposing end of the bar. An intermediate member 164 may
horizontal 142 , vertical 144 , and/ or cross 146 members may be a cantilevered member extending from a horizontal
be composed of a differentmaterial than other members. In member 142 within the substructure box 140. In some
some embodiments , a substructure box 140 may have panels 50 embodiments , an intermediate member 164 may have one or
or siding on one or more sides of the box . For example , a more gussets or brackets configured to stiffen the member
rectangular substructure box 140 having four vertical sides against upward rotation . An intermediate member 164 may
and two horizontal sides may have panels or siding on three have generally any suitable size and cross sectional shape .
vertical sides, thus partially enclosing the box . In other Further, an intermediate member 164 may be a steel, alu
embodiments , a substructure box 140 may have a more open 55 minum , wood , plastic , or other material member. In other
box design , such that the box is defined by members 142 , embodiments, a support bar 160 may connect at or near both
144, 146 with little or no siding or other substantial struc ends to intermediate members 164 . In still other embodi
tural elements . In some embodiments, a substructure box ments , a support bar 160 may connect to the substructure
140 may have forklift pockets or other means to facilitate box 140 at other locations along the bar and to various points
lifting or moving the box . 60 of the box . A substructure box 140 may have any suitable
In some embodiments , a substructure box may have at number of support bars 160 . In some embodiments , a
least one face with limited cross members and limited upper substructure box 140 may have four support bars 160 , as
and lower horizontal members or siding . For example , as shown in FIGS . 2B and 3B .
seen from the top views of FIGS. 2B and 3B , at least one support bar 160 may connect to the substructure box
side of the substructure box 140 may have a gap in an upper 65 140 using one or more hinged connections 162 . For
horizontal member 142u . That is, the top of at least one example, a support bar 160 may have a hinged connection
vertical side face may be defined by an upper horizontal 162 at or near each end of the support bar, connecting the
US 9 ,988 ,807 B2
10
support bar to the box . For example , as shown in FIG . 2B , continuous support bar spanning between the horizontal
each support bar 160 may connect to a horizontal member members 142 may distribute the lifting load of the box 140
142 with a first hinged connection 162 and an intermediate members of all four side faces of the box.
member 164 with a second hinged connection . The hinged Each support bar 160 may be configured to rotate from a
connections 162 may use any suitable hinge mechanism . In 5 lifting position , as shown in FIGS . 2A and 2B to a clearance
other embodiments , one or more support bars 160 may position , as shown in FIGS. 3A and 3B . As shown , the
couple to the substructure box 140 using a fixed connection support bars 160 may be positioned generally perpendicular
or any other type of connection or coupling mechanism . In to two upper horizontal members 142u of the substructure
some embodiments , a hinged connection 162 may include a box 140, and generally parallel to two upper horizontal
swing arm 161 and a stopping element 163. 10 members of the substructure box . It may be appreciated the
In some embodiments, a support bar 160 may couple to support bars 160 may thus each be perpendicular to two
the hinged connection 162 via a swing arm 161. A swing arm lower horizontal members 142f and parallel to two lower
161may be a connector extending from the hinged connec - horizontal members . In the lifting position , the support bars
tion 162 and configured to rotate with the support bar 160 160 may each be positioned a distance ( d ) away from a
and position the support bar a distance away from the hinge . 15 closest, parallel upper horizontal member 142u . In some
The swing arm 161 may generally be positioned perpen - embodiments , distance ( d ) may generally be the distance
dicular to the support bar 160. As with the support bar 160 , between a hinged connection 152 of the bar and a closest,
a swing arm 161 may have a lifting position , as shown in parallel upper horizontal member 142u . In the lifting posi
FIG . 2A , and a clearance position , as shown in FIG . 2B . In tion , the hinged connections 162 may position each support
the clearance position , a swing arm 161 may generally be 20 bar 160 vertically lower than the upper horizontal members
positioned adjacent to a face , such as an upper face of the 142u , as shown in FIG . 2A . In the lifting position , the
substructure box . The swing arm 161 may be configured to support bars 160 may be positioned below the upper hori
rotate downward into a lifting position . The swing arm 161 zontal members 142u with enough clearance such that the
may generally have any suitable size and shape configured jacking system 150 may suitably couple to the bars . To move
to position the support bar 160 . The swing arm 161 may be 25 to a clearance position , the support bars 160 may swing
constructed of steel, aluminum , wood , plastic , or any suit upward and outward from the lifting position , each bar
able material. moving toward its closest, parallel upper horizontal member
A stopping element 163 may be configured to provide a 142u . As shown in FIGS. 3A and 3B , each support bar 160
stopping point for the hinged mechanism 162 . For example , may be positioned adjacent to its closest, parallel upper
in some embodiments , the stopping element 163 may stop 30 horizontal member 142u in the clearance position . The
the swinging action of the hinged mechanism 162 such that hinged mechanisms 162 and swing arms 161 may move the
swing arm 161 and support bar 160 are positioned in the support bars 160 automatically or manually between the
lifting position . That is , the stopping element 163 may lifting and clearance positions . In some embodiments , for
prevent the swing arm 161 and support bar 160 from example , the hinged mechanisms 162, swing arms 161,
swinging further inward than the lifting position . The stop - 35 and / or support bars 160 may be hydraulically actuated
ping element 163 may be a stationary element extending and / or locked into position . It may be appreciated that in
from a member of the substructure box 140 , such as an upper other embodiments, the support bars 160 may be fixed in a
horizontal member 142u , as shown in FIGS. 2A and 3A . In lifting position , clearance position , or other configuration .
some embodiments , a stopping element 163 may be config In some embodiments , a support bar 160, hinged mecha
ured to operate in conjunction with an secondary stopping 40 nism 162, and swing arm 161 may additionally or alterna
element 163a . For example , the secondary stopping element tively be configured to couple stacked substructure boxes
163a may be positioned on or near the support bar 160 140 together. For example , FIG . 5 illustrates a vertical stacks
and /or swing arm 161, as shown in FIG . 3A , such that the of substructure boxes 140 housing a lifting cylinder 150. The
element may rotate with the swing arm and support bar. The first substructure box 140a of the stack is shown with fixed
secondary stopping element 163a may be configured to 45 support bars 160 . The second 140b and third 140c substruc
couple to , fit within , receive , join with , or generally be ture boxes are shown with support bars 160 in a clearance
positioned adjacent to the stopping element 163 . In this way, position . The fourth substructure box 140d is shown with
as the support bar 160 and swing arm 161 swing downward support bars 160 in a lifting position . As shown, some
on the hinged mechanism 162 into the lifting position , the substructure boxes 140 may have a coupling saddle 170
stopping element 163 and secondary stopping element 163a 50 affixed to a coupling support 172 near a surface or face of the
may connect to prevent the support bar and swing arm from substructure box , such as a lower face defined by lower
rotating further inward . horizontal members 1421. The coupling support 172 may
The hinges 162 may be configured such that the support extend from a lower horizontal member 142f in some
bars 160 may move radially upward and outward , away from embodiments . In other embodiments, the coupling support
the center of the substructure box 140 . The hinges 162 may 55 172 may extend from an intermediate member or other
be configured to move the support bars 160 approximately element coupled to or near the lower face of the box 140 .
90 degrees from a lifting position to a clearance position . The coupling support 172 may extend perpendicular to the
FIGS. 2A and 2B illustrate the support bars 160 in a lifting lower horizontal members 142f. The coupling support 172
position, according to some embodiments, while FIGS. 3A may have a coupling saddle 170 . The coupling saddle 170
and 3B illustrate the support bars in a clearance position , 60 may be configured to couple to an object such as a support
according to some embodiments . bar 160 of a substructure box 140. That is , each saddle 170
As described more fully below , support bars 160 may be may generally be configured to receive a support bar 160 ,
configured for providing a lift point for engagement by a such that the support bar may be positioned within the
jacking system 150 to raise and lower the substructure box saddle . In some embodiments , the saddle 170 may have a
140. It may be appreciated that providing two aligned 65 circular or semi-circular shape for receiving the support bar
support bars 160, each configured between a horizontal 160 . In other embodiments , the saddle 170 may have any
member 142 and an intermediate member 164 , rather than a suitable shape . Each saddle 170 may have a cover or clamp
US 9 ,988 ,807 B2
174 in some embodiments . The cover or clamp 172 may be late 154 may be configured to bear a load , such as the load
configured to close over the support bar 160 or other object of the dead load of the drill rig 100 , for example.
in order to secure the support bar to the saddle 170 . The T he telescoping cylinder 152 may be a hydraulic , pneu
cover or clamp 174 may secure or help to secure a support matic , or other extendable cylinder. In some embodiments ,
bar 160 in place within the saddle 170 . The cover or clamp 5 for example , the telescoping cylinder 152 may have a series
174 may prevent or mitigate movement of the support bar of cylinders that progressively decrease in diameter, such
160 within the saddle 170 . In some embodiments, the cover that each cylinder may be configured to receive the next
or clamp 174 may be connected to the saddle 170 via a cylinder. In other embodiments , the telescoping cylinder 152
hinged connection, for example. The cover or clamp 174 may use other mechanisms to lengthen and shorten . The
may by controlled manually or automatically . For example , " telescoping cylinder 152 may generally facilitate raising and
in some embodiments, the covers or clamps 174 may be lowering of the head 155 . The telescoping cylinder 152 may
hydraulically actuated and /or locked into place . In some be comprised of steel or other materials . In some embodi
embodiments , a substructure box 140 may have four cou - ments , the telescoping cylinder 152may be a relatively large
pling saddles 170 to correspond with four support bars 160 16 diameter and low pressure cylinder. In other embodiments ,
of an adjacent box . In other embodiments , a substructure the telescoping cylinder 152 may have any suitable diameter
box 140 may have any suitable number of coupling saddles and pressure .
170 . The bearing plate 154 may be a steel or other plate
With continue reference to FIG . 5 , in some embodiments , configured to transfer the weight of the substructure 130 or
support bar 160 and swing arm 161 may be configured to 20 drill rig 100 to the ground surface , drilling pad , or other
rotate upward and outward past the clearance position via surface. The bearing plate 154 may generally have any size
the hinged mechanism 162. That is, the hinged mechanism and shape. The bearing plate 154 may generally be sized to
162may have a range of rotation that allowsthe support bar provide a stable base when the telescoping cylinder 152 is
160 to swing upward into a coupling position , as shown in extended . In some embodiments , the bearing plate 154 may
FIG . 6 . The coupling position may position the support bar 25 be sized to facilitate lateral movement of the plate with
160 above , or partially above , the upper face of the sub - respect to the telescoping cylinder 152 , as described more
structure box 140 defined by upper horizontal members fully below with respect to the walking apparatus .
142u . In the coupling position , the support bar 160 may be The head 155 may be positioned on the telescoping
configured to be positioned within the coupling saddle 170 cylinder 152 and may be configured with one or more
of an adjacent box 140 . FIG . 6 illustrates support bars 160 30 attachment means, such as saddles 156 . The head 155 may
in coupling positions and arranged within coupling saddles generally have any suitable shape configured to position the
170. For example , the support bars 160 of the third sub saddles 156 . The head 155 may generally raise and lower as
structure box 140c may swing upward into the coupling a unit coupled to the telescoping cylinder 152 . In some
position to couple to the saddles 170 of the second substruc
174 3535 embodiments
ture box 140b . As shown in FIG . 6 , the covers or clamps 174 € , as shown in FIGS. 8A -8B , the head 155 may
may close to lock the support bars 160 into place within the have a collar portion 155a , an upper portion 155b , one or
saddles 170. more angled portions 155c , and a center portion 155d . The
Turning now to FIGS. 7A , 7B , and 7C , a support bar 160 collar portion 155a may couple the head 155 to the tele
and swing arm 161, and hinged mechanism 162 are shown scoping cylinder 152 . The collar portion 155a may generally
in each of a lifting position , clearance position , and coupling 40 have any shape, and in some embodiments ,may be a circular
position , respectively. FIG . 7B additionally shows a cou - ring shape that encircles the telescoping cylinder 152 and /or
pling saddle 170 , coupling member 172, and clamp 174 center portion 155d . The collar portion 155a may generally
positioned above the support bar 160 . As shown in FIG . 7C , have any suitable thickness . One or more angled portions
in the coupling position , the coupling saddle 170 may be 155c may extend from the collar 155a . In some embodi
engaged by the support bar 160 , and the cover or clamp 174 45 ments , four angled portions 155cmay extend from the collar
may close over the support bar to secure it in place . In this portion 155a . In some embodiments , the angled portions
way, an upper box having the coupling saddle 170 may be 155c may additionally or alternatively couple to or extend
coupled to a lower box having the support bar 160 . In other from the center portion 155d . The angled portions 155c may
embodiments, other coupling mechanisms may be used to be configured to support the upper portion 155b . The angled
join adjacent substructure boxes 140 . For example , substruc - 50 portions 155c may have any suitable size and shape. The
ture boxes 140 may be pinned together using lugs and pins center portion 155d may generally be an extension of the
in some embodiments . In other embodiments, adjacent telescoping cylinder 152 in some embodiments, and may
boxes 140 may be clamped together using locks such as provide a base for the head 155 . For example , in some
International Standards Organization (ISO ) shipping con embodiments, the center portion 155d may be configured to
tainer locks. 55 receive or house the telescoping cylinder 152 when in a
A substructure box 140 may be configured to house a lowered position . The center portion 155d may have a
jacking system 150 . Ajacking system 150 may be or include cylindrical shape in some embodiments. In other embodi
a telescoping hydraulic and/or pneumatic lifting system ments, the center portion 155d may have any suitable shape .
having cylinders , screw and /or gear mechanisms, chain and The center portion may extend to height higher than that of
sprocket mechanisms, cable and pulley / roller mechanisms, 60 the upper portion 155d , as shown in FIGS. 8A -8B . The
and /or other lifting mechanisms. FIG . 8A shows a jacking upper portion 155b may hold the saddles 156 or other
system 150 in a lowered position , and FIG . 8B shows a attachment mechanisms. The upper portion 155b may be
jacking system in a raised position . As shown in FIGS. 8A rectangular in some embodiments . For example , the upper
and 8B , the jacking system 150 may have a telescoping portion 155b may have four straightmembers arranged in a
cylinder 152, a bearing plate 154 , a head 155 , and one or 65 rectangular configuration . In some embodiments , a saddle
more saddles 156 . The telescoping cylinder 152 may be 156 may be arranged at each corner of the rectangular upper
configured to automatically lengthen or shorten . The bearing portion 155b . In other embodiments , the upper portion 155b
US 9, 988, 807 B2
13 14
may be round or have any suitable shape . In other embodi- walking apparatus 158 . FIG . 9 shows a top down view of a
ments , the head 155 may have other shapes or configura jacking system 150 with skid foot movement apparatus 158 .
tions. In some embodiments , the skid foot movement or walking
In some embodiments , the head 155 may generally have apparatus 158 may facilitate movement of the assembled
an H - shape configured for operating within a substructure 5 drilling rig 100 between wellbore locations on a pad drilling
box 140, for example . Turning to FIGS . 10B and 11B , top site . A walking apparatus 158 may be configured to operate
down views of a jacking system 150 arranged within a by way of a hydraulic pump, for example . In some embodi
substructure box 140 are shown with support bars 160 in a ments , such a hydraulic pump may operate one or more
lifting position and in a clearance position , respectively. As walking apparatuses 158 on a drilling rig 100 .
shown in FIG . 11B , the head 155 may generally have an 10 The jacking system 150 may be configured to operate
H - shaped configuration . For example, the upper portion within one or more substructure boxes 140 in some embodi
155b may have a rectangular shape . The saddles 156 may ments . FIGS. 10 -11 show side and top views of a jacking
extend from each of four corners of the upper portion 155b , system 150 arranged within a substructure box 140 . Each
thus creating the H -shape . As shown in FIG . 11B , such an jacking system 150 may generally be configured to raise the
H - shape configuration may allow the jacking system 150 to 15 substructure box 140 by attaching to the support bars 160
raise and lower through the substructure box 140 when the and operating the telescoping cylinder 152 . As shown in
support bars 160 of the box are in a clearance position , FIG . 10A , the support bars 160 may generally be configured
without disturbing the intermediate members 164 , for to bepositioned within the saddles 156 ofthe jacking system
example . As shown in FIG . 10B , the H - shape may addition - 150. The jacking system 150 may raise slightly to attach to
ally allow the jacking system 150 to couple to the support 20 the support bars 160 . When attached to the support bars 160 ,
bars 160 without disturbing the intermediate members 164 the jacking system 150 may operate to raise or lower on its
or other components. That is, the four saddles 156 extending telescoping cylinder 152 to raise or lower the substructure
from the upper portion 155b may couple to each of the box 140 . FIG . 10B shows a top down view of the jacking
support bars 160 outside the rectangular frame of the upper system 150 and substructure box 140 of FIG . 10A . FIGS.
portion . In other embodiments , the jacking system 150 , head 25 11A - 11B illustrate side and top views of the jacking system
155 , and/ or upper portion 155b may have any suitable shape 150 within the substructure box 140 with the support bars
or configuration . 160 in a clearance position . As shown discussed above , the
With continued reference to FIGS. 8A - 8B , the one or jacking system 150, including for example the head 155 of
more saddles 156 may be configured to couple to an object the jacking system , may generally have an H - shape config
such as a support bar 160 of a substructure box 140 . That is , 30 ured to couple to the support bars 160 in a lifting position
each saddle 156 may generally be configured to receive a and /or clear the support bars in a clearance position , while
support bar 160, such that the supportbar may be positioned also clearing the intermediate members 164 , as shown in
within the saddle . In some embodiments , the saddle 156 may F IGS . 10B and 11B . In some embodiments , a substructure
have a circular or semi-circular shape for receiving the box 140 may have limited or no cross members 146 or siding
support bar 160 . In other embodiments , the saddle 156 may 35 on a face, such as a top face shown in FIG . 11B , in order for
have any suitable shape. Each saddle may have a cover or a jacking system 150 to telescope through the box . FIGS .
clamp 157 in some embodiments. The cover or clamp 157 12A and 12B show more detailed top down views of the
may be configured to close over the support bar 160 or other jacking system 150 within a substructure box 140 , wherein
object in order to secure the support bar to the saddle 156 . the bearing plate 152 and walking apparatus 158 may be
The cover or clamp 157 may secure or help to secure a 40 seen .
support bar 160 in place within the saddle 156 . The cover or It may be appreciated that the squared C - shape of the
clamp 157 may prevent ormitigate movement of the support substructure box 140 may allow the box to receive the
bar 160 during raising , lowering , or other movement of the jacking system 150 such that the box may be slid or wrapped
substructure box 140 by the jacking system 150 . In some around the jacking system from the side . FIGS. 13A and 13B
embodiments, the cover or clamp 157 may be connected to 45 illustrate opposing side views of a jacking system 150 lifting
the saddle 156 via a hinged connection , for example . The a vertical stack of two substructure boxes 140 such that a
cover or clamp 157 may by controlled manually or auto - third substructure box may be placed at the bottom of the
matically . For example , in some embodiments, the covers or vertical stack . FIG . 13A illustrates an uppermost substruc
clamps 157 may be hydraulically actuated and/ or locked into ture box 140 having a closed box shape, and a second and
place . In other embodiments, other coupling mechanisms 50 third lower boxes having a squared C - shape , as discussed
may be used to couple a support bar 160 or other object to above . That is, some substructure boxes 140 may at least one
the jacking system 150 . In some embodiments, a jacking vertical side face with limited cross 146 and horizontal 142
system 150 may have four saddles 156 or other coupling members . In this way , the C - shaped substructure box 140
mechanisms. In other embodiments , a jacking system 150 may be positioned around the lifted jacking system 150 . The
may have more or fewer saddles 156 or other coupling 55 open vertical side face of the box 140 may accommodate the
mechanisms. telescoping cylinder 154 and bearing plate 152 such that the
In some embodiments, a jacking system 150 may addi- box may be positioned about the jacking system 150 and
tionally be or include a means for moving the drilling rig beneath the vertical stack of boxes . FIG . 13B illustrates an
100 . For example , in some embodiments , a skid foot move - opposing side view of the vertical stack of boxes 140 lifted
ment, or walking, apparatus 158 having one or more bear - 60 by the jacking system 150 such that a third box may be
ings may be positioned between and operatively coupled to positioned beneath the stack . The opposing vertical side face
each telescoping cylinder 152 and its respective bearing shown in FIG . 13B may have horizontal members 142
plate 154 so as to facilitate skid , or walking, movement of extending between vertical members 144, and cross mem
the drilling rig 100. That is , each bearing plate 154 may b ers 146 extending between horizontal members .
additionally operate as a skid foot for the walking apparatus 65 When raising or lowering a substructure box 140, the
158. In this way, the bearing plate 154 may be wide enough jacking system 150 may generally exert a pushing or pulling
to accommodate lateral movement along the bearings of the force on the substructure bars 160 . It may be appreciated that
US 9 ,988,807 B2
15 16
the hinged mechanisms 162 may be configured so as to used to erect the mast 110 . For example , while in a hori
prevent or mitigate the hinging motion during movement of zontal position , the hydraulic lifting cylinders 112 may
the jacking system 150 . Specifically, opposing sets of hinged extend , as shown in FIG . 15 , to raise themast 110 onto mast
mechanisms 162 , swing arms 161, and stopping elements shoes 114 on the drill floor 120 . As shown in FIG . 16 , the
163 may have opposite directional configurations . As shown 5 mast 110 may be pinned to the mast shoes 114 . The
for example in FIGS . 10A and 11A , two opposing hinged hydraulic lifting cylinders 112 may be positioned so as to
mechanisms 162 may be aligned with one another and may erect the mast, as shown in FIG . 17 , and may extend to
couple to opposing support bars 160 . The two opposing position the mast upright, as shown in FIG . 18 . The lifting
hinged mechanisms 162 may be configured to rotate in cylinders 114 may be detached after the mast has been
opposing directions, such that for example , one support bar 10 erected , as shown in FIG . 19 . Erection of the mast using
160 is configured to rotate from the clearance position to the hydraulic lifting cylinders is described more fully in U . S .
lifting position in a clockwise direction , while the opposing Pat. No. 9,091, 126 , entitled Mobile Drilling Rig with Tele
support bar is configured to rotate from the clearance scoping Substructure Boxes , filed Apr. 16 , 2013 , incorpo
position to the lifting position in a counterclockwise direc rated herein by reference in its entirety. In other embodi
tion . In this way , opposing swing arms 161 and stopping 15 ments , other devices or means may be used to erect the mast
elements 163 may likewise rotate in opposing directions . 110 or otherwise position the mast for drilling operations.
The opposing rotation directions, combined with the stop In some embodiments, the substructure 130 may be
ping elements 163 , may generally prevent or mitigate rota assembled or completed at the drilling site . Where the
tion at the hinged mechanisms 162 while the substructure substructure 130 includes one or more vertical stacks of
box 140 is raised , lowered , or otherwise moved on the 20 substructure boxes 140 , for example , the substructure boxes
jacking system 150. may be assembled and / or stacked at the drilling site. In this
While the support bars 160 are described as coupled to the way, the substructure boxes 140 may be delivered or oth
substructure boxes 140 , and the saddles 156 coupled to the erwise brought to the drilling site separately on trailers ,
jacking system 150, it may be appreciated that the position - trucks, or by other means .
ing of the bars and saddles may be generally reversed . That 25 As shown in FIG . 19 , the substructure 130 may have a
is , in some embodiments , one or more support bars 160 may first layer 140a of substructure boxes . The first layer 140a of
extend from a jacking system 150 . Further, in some embodi- substructure boxes may include one or more boxes coupled
ments, one or more saddles 156 , optionally having a clamp to the drilling floor 120 of the rig 100 . Substructure boxes
or cover 157, may extend from a substructure box 140 . The 140 for the first layer 140a may be placed at various
one or more saddles 156 may open downward , so as to 30 locations beneath the drilling floor 120 . For example, in
receive a support bar 160 from below . The one or more some embodiments , one or more boxes 140 may be placed
saddles 156 may be configured to rotate from a lifting at each corner of a rectangular drilling floor 120. In other
position to a clearance position , and in some embodiments embodiments , substructure boxes 140 may be placed along
may each rotate on a swing arm 161 coupled to a hinged the full width and/ or length of the drill floor 120 . In some
mechanism 162 . In this way, the support bar ( s ) 160 of the 35 embodiments , substructure boxes 140 may be placed in one
jacking system 150 may be configured to raise upward and or more rows beneath the drill floor 120 . For example , a first
into the saddle (s ) 156 when the saddle (s ) are in a lifting row of substructure boxes 140 may be placed on a driller
position . The clamp or cover (s ) 157 may close around a side of the drill rig 100 , spanning the width of the drill floor
bottom or lower surface of the support bar(s ) 160 to secure between a setback side 100a and a drawworks side 100b as
the one or more bars in place against the one or more saddles 40 shown in FIG . 19 . A corresponding row may be placed on an
156 . When the saddle ( s ) 156 are in a clearance position , the off- driller side of the rig . In some embodiments , each row of
jacking system 150 and support bars 160 may operably pass substructure boxes 140 may include a substructure box at
through an upper face of the substructure box 140 . each end of the row and one or more spreader boxes 145
Furthermore , where the saddles 156 are positioned on the between the two substructure boxes. In other embodiments ,
substructure boxes 140 , a box may also have coupling bars 45 substructure boxes 140 may be placed in other configura
in some embodiments . For example , a saddle 156 that tions to form a first layer 140a beneath the drill floor 120 .
extends from a substructure box 140 may be configured to In some embodiments , additional layers of substructure
swing upward into a coupling position . The saddle 156 may boxes 140 may be added to the substructure 130 , so as to
be configured to couple to a coupling bar or other member elevate the drill floor 120. Generally, substructure boxes 140
extending from an adjacent substructure box . 50 may be added by raising the drill floor 120 and first layer
Assembly of the drilling rig 100 and substructure 130 will 140a using the one or more jacking systems 150 . The
now be described with respect to FIGS. 14 - 35 . jacking systems 150 may raise the drill floor 120 and first
A drilling rig 100 may generally be transported to a layer 140a high enough off the ground or other surface to
drilling site , such as a pad drilling site , by one or more accommodate a second layer of substructure boxes 140. The
truck /trailer combinations, rail cars , or other modes of 55 jacking systems 150 may be delivered or otherwise brought
transportation . In this way, the drilling rig 100 may be to the drilling site by trucks, trailers , or by other means.
transported in separate components that may be assembled FIGS. 20A - F illustrate a process of raising the first layer
at the drilling site . The drill floor 120 , for example, may be 140a of substructure boxes , according to some embodi
delivered to the drilling site in one or more components . In ments.
some embodiments, the mast 110 may be transported to a 60 FIG . 20A illustrates a side view of a first layer of
drilling site , separate from the drilling floor 120 or substruc - substructure boxes 140a and two jacking systems 150 out
ture 130 , and assembled on the drill floor at the drilling site . side of the substructure . While only two jacking systems 150
In some embodiments , the mast 110 may be transported in are shown in FIGS. 20A - F , it may be appreciated that a
a horizontal position , as shown in FIG . 14, and thus may be jacking system may be used at each corner of the substruc
erected to a vertical position at the drilling site . Various 65 ture 130 to raise the drill floor 120 and substructure . In other
devices and / or means may be used to erect the mast 110 . In embodiments , any number of jacking systems 150 may be
some embodiments , hydraulic lifting cylinders 112 may be used to raise the drill floor 120 and substructure 130 . As
US 9, 988, 807 B2
17 18
shown in FIG . 20B , the jacking systems 150 may be placed other embodiments , one ormore shear pins may couple each
within the first layer 140a of substructure boxes. For substructure box 140 of the second layer 140b to one or
example , a jacking system 150 may be placed within a more boxes ofthe first layer 140a . In other embodiments , the
substructure box 140 situated at each corner of the first layer first 140a and second 140b layers may be coupled using any
140a . In some embodiments , the support bars 160 of the 5 suitable mechanism , such as but not limited to clamps or
substructure boxes 140 within the first layer 140a may have hydraulically actuated pins.
fixed connections to the boxes, as shown in FIG . 20 . In other FIG . 21 shows the first layer 140a , drill floor 120 , and
embodiments, the support bars 160 may have a hinged mast 110 elevated by the jacking systems 150, such that the
connection 162 or other movable connection , such that the dead load of the drill rig 100 is sustained by the bearing
support bars may be lowered to the lifting position to couple 10 plates 154 of the jacking systems. As described , with respect
with the jacking system 150 . As shown in FIG . 20C , each to FIG . 20 , the rig 100 may be elevated high enough to
jacking system 150 may be raised a distance within the first accommodate additional substructure boxes 140 being slid
layer 140a so as to connect with the one or more support bars beneath the first layer 140a . FIG . 22 illustrates substructure
160 within the substructure boxes 140. In some embodi boxes 140 positioned around each jacking system 150 to
ments , each jacking system 150 may couple to the one or 15 form a second layer 140b . As shown in FIG . 23 , after the
more support bars 160 within a box 140 by positioning each second layer 140b has been positioned within the substruc
support bar within a saddle 156 of the jacking system and ture 130 and secured to the first layer 140a by coupling
securing the bar in place with clamp 157 . In other embodi- saddles, shear pins, or other mechanisms, the jacking sys
ments, the jacking systems 150 may couple to the support tems 150 may release the support bars 160 and return to their
bars 160, or may generally couple to the substructure boxes 20 lowered position . In this way, the dead load of the rig 100
140, using other coupling mechanisms. may be transferred off of the bearing plates 154 and onto the
As shown in FIG . 20D , the jacking systems 150 may raise first 140a and second 140b layers of the substructure .
further on their telescoping cylinders 152 to elevate the drill Support bars 160 within the first layer 140a of substructure
floor 120 and first layer 140a off of the ground surface , boxes may move to a clearance position , in some embodi
drilling pad , or other surface . In this way , the dead load of 25 ments , when no longer engaged with the jacking systems
the drill rig 100 may be transferred from substructure boxes 150 . It may be appreciated that the procedure just described
140 onto the jacking systems 150 . Particularly , the dead load for adding a layer of substructure boxes 140 to the substruc
of the drill rig 100 may be transferred to the bearing plates ture 130 may generally be repeated until the drill floor 120
154 of the jacking systems 150. The jacking systems 150 reaches a desired height above the ground surface , drilling
may elevate the first layer 140a high enough to place 30 pad , or other surface .
additional substructure boxes 140 beneath the first layer. The Turning now to FIGS. 24A - E , a third layer of substructure
first layer 140a may be elevated such that a lower surface of boxes 140 may be added to the substructure 130 in some
the first layer is positioned a distance above the ground or embodiments . As shown in FIG . 24A , support bars 160
other surface that is higher than the height of the substruc - within substructure boxes 140 of the second layer 140b may
ture boxes 140 to be placed beneath the first layer. For 35 be in a clearance position . Before raising the substructure
example , where the substructure boxes 140 to be added 130 , the support bars 160 may be lowered to a lifting
beneath the first layer 140a are six feet in height, the jacking position, as shown in FIG . 24B . The support bars 160 may
systems 150 may raise the first layer such that the bottom be lowered using hinged connections 162, as discussed
surface is more than six feet off of the ground surface , above , in some embodiments . In other embodiments, the
drilling pad , or other surface, so as to accommodate the 40 support bars 160 may initially be in a lowered position or
additional boxes . In some embodiments, the jacking systems may be fixed in a lowered position . The jacking systems 150
150 may raise the first layer 140a to a height of six feet, six may be coupled to the support bars 160 via the saddles 156
inches off the ground surface , drilling pad , or other surface . in some embodiments . In some embodiments , the jacking
As shown in FIG . 20E , one or more substructure boxes systems 150 may be raised slightly in order to connect with
140 may be inserted beneath the first layer 140a , so as to 45 the support bars 160 . As shown in FIG . 24C , the jacking
form a second layer 140b of substructure boxes . The sub - systems 150 may transfer the dead load of the rig 100 from
structure boxes 140 may be positioned using a forklift, the substructure 130 onto the bearing plates 154 by extend
rubber tire crane , bulldozer , or other means. In some ing the hydraulic cylinders 152 to elevate the rig . The
embodiments, a substructure box 140 may be placed at each additional substructure boxes 140 may be slid beneath the
corner of the substructure 130 , such that a box is positioned 50 second layer 140b to form a third layer 140c of boxes. Each
at or about each jacking system 150 in some embodiments . substructure box 140 of the third layer 140c may be posi
That is, in some embodiments , each box of the second layer tioned around or generally at a jacking system 150 in some
140b may be slide beneath the first layer 140a , such that embodiments, as shown in FIG . 24D . In some embodiments ,
each box of the second layer is positioned around or gen a box 140 may be positioned beneath each box of the second
erally surrounding the raised telescoping cylinder 152 a 55 layer 140b , creating vertical stacks of boxes. As shown in
jacking system 150 . As described previously , the substruc - FIG . 24E , the jacking cylinders 150 may be lowered , such
ture boxes 140may have a gap in the horizontal 142, vertical that the second layer 140b is positioned on top of the third
144 , and cross members 146 and / or any siding , and / or may layer 140c . The third layer 140c may be coupled to the
have a generally squared C - shape , in order to accommodate second layer 140b via coupling saddles, shear pins , or other
the box being slid around a telescoping cylinder 152 . As 60 coupling mechanisms. The jacking systems 150 may release
shown in FIG . 20F , the jacking systems 150 may lower the the support bars 160 or otherwise disconnect from the
first layer 140a onto the second layer 140b of boxes . In some second layer 140b and may lower toward the ground surface ,
embodiments, the first layer 140a and second layer 140b of drilling pad , or other surface . Thus , the dead load of the rig
boxes may be coupled together. For example , as described 100 may be transferred from the jacking systems 150 to the
above, the support bars 160 may rotate upward into a 65 substructure 130 .
coupling position and couple to coupling saddles in order to FIG . 25 shows the first layer 140a , second layer 140b ,
couple the layers ofboxes together in some embodiments . In drill floor 120 , and mast 110 elevated by the jacking systems
US 9 ,988,807 B2
20
150, such that the dead load of the drill rig 100 is sustained 140a , second 1406 , third 140c, and fourth 140d layer of
by the bearing plates 154 of the jacking systems. As substructure boxes, wherein each of the first , second , and
described , with respect to FIG . 24 , the rig 100 may be third layer of boxes has a coupling saddle 170 . As shown in
elevated high enough to accommodate additional substruc - FIG . 30 , the coupling saddles 170 and support bars 160 may
ture boxes 140 being slid beneath the second layer 140b . 5 be used to couple each layer of boxes 140 together. In each
FIG . 26 illustrates substructure boxes 140 positioned around of FIGS. 29 and 30 , the fourth layer of boxes 140d has
each jacking system 150 to form a third layer 140c. In some support bars 160 in a lifting position and coupled to jacking
embodiments, one or more spreader boxes 145 may be systems 150 . In some embodiments , the support bars 160 of
positioned as part of the third layer 140c . For example , a
spreader box 145 may be placed on each side of the 10 the fourth level of boxes 140d may be released from the
jacking systems 150 and may be rotated upward into the
substructure 130, each spreader box positioned between two coupling position so as to engage with the coupling saddles
corner substructure boxes 140 of the third layer 140c . In 170 of the third layer of boxes 140c , thereby coupling the
other embodiments , one or more spreader boxes 145 may be
positioned at any suitable location within the substructure , third and fourth layers together.
include at any substructure level. A spreader box 145 may 15 FIG . 31 shows the first layer 140a, second layer 140b ,
provide for storage space or work space below the drill floor third layer 140c, drill floor 120 , and mast 110 elevated by the
120 . In some embodiments, access may be provided for jacking systems 150 , such that the dead load of the drill rig
reaching one or more spreader boxes 145 beneath the drill 100 is sustained by the bearing plates 154 of the jacking
floor 120 . systems. As described , with respect to FIG . 28 , the rig 100
As shown in FIG . 27 , after the third layer 140c has been 20 may be elevated high enough to accommodate additional
positioned within the substructure 130 and secured to the substructure boxes 140 being slid beneath the third layer
second layer 140b by shear pins or other mechanisms, the 140c . FIG . 32 illustrates substructure boxes 140 positioned
jacking systems 150 may release the support bars 160 and around each jacking system 150 to form a fourth layer 140d .
return to their lowered position . In this way , the dead load of After the fourth layer 140d has been positioned within the
the rig 100 may be transferred off of the bearing plates 154 25 substructure 130 and secured to the third layer 140c by
and onto the first 140a , second 140b , and third 140c layers coupling saddles , shear pins , or other mechanisms, the
of the substructure. Support bars 160 within the second layer jacking systems 150 may release the support bars 160 and
140b of substructure boxes may move to a clearance posi return to their lowered position . In this way , the dead load of
tion , in some embodiments, when no longer engaged with the rig 100 may be transferred off of the bearing plates 154
the jacking systems 150 . 30 and onto the first 140a , second 140b , third 140c , and fourth
Turning now to FIGS. 28A - E , a fourth layer of substruc 140d layers of the substructure . Support bars 160 within the
ture boxes 140 may be added to the substructure 130 in some third layer 140c of substructure boxes may move to a
embodiments. As shown in FIG . 28A , support bars 160 clearance position , in some embodiments , when no longer
within substructure boxes 140 of the third layer 140c may be 25 engaged with
in a clearance position . Before raising the substructure 130 , 35 engFIGS. 33A - the
Q
jacking systems 150 .
illustrate the steps of raising the drill rig 100
the support bars 160 may be lowered to a lifting position , as
shown in FIG . 28B . The support bars 160 may be lowered to add a second layer 140b , third layer 140c , and fourth layer
using hinged connections 162 , as discussed above , in some 140d to the substructure 130 , as discussed above with
embodiments. In other embodiments , the support bars 160 respect to FIGS. 20 - 32 . It may be appreciated that more or
may initially be in a lowered position or may be fixed in a 40 fewer layers of substructure boxes 140 may be added to the
lowered position . The jacking systems 150 may be coupled substructure 130. Generally, the substructure 130 may have
to the support bars 160 via the saddles 156 in some embodi- enough layers or may generally be elevated to a height to
ments . In some embodiments , the jacking systems 150 may accommodate blow out preventers , Christmas tree assem
be raised slightly in order to connect with the support bars blies , or other components of the drilling operation . In some
160. As shown in FIG . 28C , the jacking systems 150 may 45 embodiments , substructure boxes 140 may be added to bring
transfer the dead load of the rig 100 from the substructure the drill floor height to between 10 and 100 feet above the
130 onto the bearing plates 154 by extending the hydraulic ground surface. In particular embodiments, substructure
cylinders 152 to elevate the rig . The additional substructure boxes 140 may be added to bring the drill floor height to
boxes 140 may be slid beneath the third layer 140c to form between 20 and 50 feet above the ground surface . In more
a fourth layer 140d of boxes . Each substructure box 140 of 50 particular embodiments , substructure boxes 140 may be
the fourth layer 140d may be positioned around or generally added to bring the drill floor height to between 20 and 30 feet
at a jacking system 150 in some embodiments , as shown in above the ground surface . For example , in at least one
FIG . 28D . In some embodiments , a box 140 may be posi - embodiment, substructure boxes 140 may be added to the
tioned beneath each box of the third layer 140c , creating substructure 130 to bring the drill floor height to 28 feet
vertical stacks ofboxes . As shown in FIG . 28E , the jacking 55 above the ground surface . The number of boxes 140 or
cylinders 150 may be lowered , such that the third layer 140c
layers of boxes needed to elevate the drill floor to a desired
is positioned on top of the fourth layer 140d . The fourth height above the ground surface may depend in part on the
layer 140d may be coupled to the third layer 140c via height of the boxes.
coupling saddles, shear pins, or other coupling mechanisms. Turning now to FIG . 34 , a side view of the substructure
The jacking systems 150 may release the support bars 160 60 130 with four layers of substructure boxes 140 is shown .
or otherwise disconnect from the third layer 140c and may FIGS. 35A and 35B show opposing side views of one of the
lower toward the ground surface , drilling pad , or other vertical stacks of substructure boxes 140 of FIG . 34 . As
surface. Thus, the dead load of the rig 100 may be trans- shown in FIG . 35A , boxes 140 of the second 1406 , third
ferred from the jacking systems 150 to the substructure 130 . 140c, and fourth 140d layers may have less bracing , such as
As discussed above , in some embodiments , support bars 65 fewer cross members 146 and horizontalmembers 142 on at
160 may be configured to rotate upward into a coupling least one side , so as to accommodate the boxes being
position . FIG . 29 illustrates a substructure 130 having a first positioned around the jacking systems 150 . As discussed
US 9,988 ,807 B2
21
above, the boxes 140 may have a generally squared C -shape substructure of the present disclosure may allow for below
so as to accommodate being placed around the jacking drill floor access to storage , work spaces , and other compo
systems 150 . nents .
In some embodiments, the drilling rig 100 with assembled As used herein , the terms “ substantially ” or “ generally ”
substructure 130 may be generally mobile . For example , the 5 refer to the complete or nearly complete extent or degree of
drilling rig 100 may be movable between wellbores on a pad an action , characteristic, property, state , structure, item , or
drilling site . The drilling rig 100 may use various movement result. For example, an object that is “ substantially ” or
mechanisms, such as walking feet or a skid movement “ generally ” enclosed would mean that the object is either
apparatus , tires such as rubber tires , rails, or othermovement completely enclosed or nearly completely enclosed . The
10 exact allowable degree of deviation from absolute complete
mechanisms. Generally, any suitable movement mechanism ness may in some cases depend on the specific context.
may be used . In some embodiments , the drilling rig 100 may However, generally speaking , the nearness of completion
be movable using walking feet. The walking feet may be will be so as to have generally the same overall result as if
separate components coupled to the substructure 130 in absolute and total completion were obtained . The use of
some embodiments . In other embodiments , the jacking 15 “ substantially ” or “ generally ” is equally applicable when
systems 150 may each have a walking or skid foot move used in a negative connotation to refer to the complete or
ment apparatus 158 . The movement of the skid footmove - near complete lack of an action , characteristic , property ,
ment apparatus 158 may generally involve raising the drill state , structure , item , or result. For example, an element,
ing rig 100 a distance off of the ground or other surface using combination , embodiment, or composition that is “ substan
the telescoping cylinder 152 , followed by a skidding step , so 20 tially free of” or “ generally free of an ingredient or element
as to move the drilling rig 100 a distance laterally or may still actually contain such item as long as there is
longitudinally. The movement of the rig 100 on the walking generally no measurable effect thereof.
feet is described more fully in U . S . Pat. No. 9 ,091,126 , In the foregoing description various embodiments of the
entitled Mobile Drilling Rig with Telescoping Substructure present disclosure have been presented for the purpose of
Boxes , filed Apr. 16 , 2013 , incorporated herein by reference 25 illustration and description . They are not intended to be
in its entirety . It may be appreciated that the vertical stack exhaustive or to limit the invention to the precise form
configuration of the substructure boxes 140 may allow the disclosed . Obvious modifications or variations are possible
drilling rig 100 to be moved , using the skid foot movement in light of the above teachings . The various embodiments
apparatuses 158 latitudinally and /or longitudinally, allowing were chosen and described to provide the best illustration of
more freedom of movement. 30 the principals of the disclosure and their practical applica
In some embodiments , the jacking systems 150 may be tion , and to enable one of ordinary skill in the art to utilize
clamped or otherwise securely coupled to the substructure the various embodiments with various modifications as are
130 prior to initiating the skid footmovement apparatus 158 . suited to the particular use contemplated . All such modifi
As shown in FIG . 34 , for example, the jacking systems 150 cations and variations are within the scope of the present
may couple to the fourth layer 140d , or otherwise bottom 35 disclosure as determined by the appended claims when
layer, of substructure boxes 140 via the saddles 156 or other interpreted in accordance with the breadth they are fairly ,
attachmentmechanism . In some embodiments , the covers or legally , and equitably entitled .
clamps 157 may close over the support bars 160 in order to We claim :
secure the support bars to the jacking systems 150 during 1 . A drilling rig with a self- elevating drill floor, the
lateral or longitudinalmovement. In other embodiments, the 40 drilling rig comprising :
jacking systems 150 may secure to the substructure 130 a mast;
using other mechanisms for lateral or longitudinal skidding a drill floor supporting the mast; and
movement. a substructure supporting the mast and drill floor, the
A drilling rig of the present disclosure may generally be substructure comprising a plurality of substructure
disassembled by variousmethods . Asmay be appreciated , a 45 boxes, wherein at least a portion of the plurality of
drilling rig of the present disclosure may generally be substructure boxes comprise at least one of:
disassembled in an opposite manner from which it was a pivotable support bar configured for raising the
assembled . That is, where assembly of the substructure substructure and for coupling to a next substructure
included the steps of raising the drill floor, inserting a layer box ; and
of substructure boxes , and pinning the substructure boxes in 50 a pivotable saddle configured for raising the substruc
place , disassembly of the substructure may generally include ture and for coupling to a next substructure box .
unpinning a layer of substructure boxes , raising the drill 2 . The drilling rig of claim 1, further comprising a jacking
floor above the unpinned boxes , such that the dead load of system comprising a telescoping cylinder and at least one of
the drilling rig is transferred to the jacking systems, and a support bar and a saddle , the jacking system configured for
removing the unpinned boxes . Once the substructure is 55 coupling to a substructure box to raise the substructure .
disassembled , the mast may be lowered and the remainder of 3 . The drilling rig of claim 1, wherein the pivotable
the drilling rig disassembled in some embodiments . support bar is hydraulically actuated .
It may further be appreciated that a substructure of the 4 . The drilling rig of claim 3, wherein the pivotable
present disclosure may be comprised of relatively small and support bar is configured to pivot between a lifting position
manageable components , such as the individual substructure 60 for raising the substructure and a coupling position for
boxes . In this way , the substructure components may be coupling to a second substructure box .
shipped or brought to a drilling site using relatively small 5 . The drilling rig of claim 1, wherein the pivotable saddle
trailers, trucks , or other means . In addition , a substructure is hydraulically actuated .
and/ or drilling rig of the present disclosure may be 6 . The drilling rig of claim 5 , wherein the pivotable saddle
assembled using relatively small vehicles , such as rubber 65 is configured to pivot between a lifting position for raising
tire cranes , bulldozers , and /or other vehicles. Moreover the
the substructure and a coupling position for coupling to a
relatively open box design of the substructure boxes and second substructure box.
US 9 ,988,807 B2
23 24
7 . The drilling rig of claim 3, wherein the pivotable drill floor when the drill floor is in a jacked position ,
support bar of each substructure box extends across the and configured for supporting the drill floor when the
substructure box . drill floor is in an unjacked position , each of the
8 . The drilling rig of claim 7 , wherein the pivotable plurality of boxes comprising a pivotable saddle con
support bar has a length shorter than a width of the sub - 5 figured for engaging a pivotable support bar of an
structure box , the width being measured in a direction adjacent box .
parallel to the pivotable support bar. 14 . The drilling rig of claim 13 , wherein the plurality of
9. The drilling rig of claim 1 ,wherein the at least a portion boxes are configured to accommodate a jack when sliding
of the plurality of substructure boxes comprises four pivot into position below the drill floor.
able support bars . 10
10 15 . The drilling rig of claim 14 , wherein each of the
10 . The drilling rig of claim 7, wherein the pivotable plurality of boxes is C -shaped when viewed from above.
support bar comprises a stopping element for securing the 16 . The drilling rig of claim 13 , wherein the plurality of
pivotable support bar in a lifting position . rality of boxes are configured for stacking on one another to raise a
11 . The drilling rig of claim 3 , wherein the plurality of
substructure boxes are configured for sliding laterally and and 1515 height
nei17 . of the drill floor.
receiving a jacking system . The drilling rig of claim 16 , wherein each of the
12 . The drilling rig of claim 11 , wherein each of the plurality of boxes includes a pivotable support bar config
plurality of substructure boxes has a C -shape when viewed ured for engagement by a saddle for lifting the box and
from above . supported drill floor.
13 . A drilling rig with a self -elevating drill floor, the 18 . The drilling rig of claim 17 , wherein the pivotable
20 support
drilling rig comprising : bar is further configured for engagement with an
a mast ; adjacent box .
a drill floor; and 19 . The drilling rig of claim 18 , wherein the drill floor
a substructure configured for supporting the mast and the os comprises four corners and is configured for lifting at each
co !its four corners .
drill floor, the substructure comprising a plurality of 25 of
011
boxes configured for sliding into position below the * * * * *

United States Patent: (10) Patent No .: US 9, 988, 807 B2

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United States Patent: (10) Patent No .: US 9, 988, 807 B2

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|HAO WATATU NA MARIA DELO NAKUWAM T U US009988807B2

(12) United States Patent ( 10) Patent No.: US 9,988,807 B2

(56 ) References Cited 2007/0272762 AL 11 /2007 Click et al.

140 140 1420

000000000 0 000000 02160

- .- Sheet 11 of 46 US 9 , 988 ,807 B2

WPMARY Foto -144 TWIY 146 144

AMH M KENSTRAMH 28C

WMJ*5AE1ZNM4O VDU AINEMAV MMMaresotaMAMANA

FIG . 33M 1406

FIG . 330 A AKAKKARA

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