US010976016B2
`
`US 10,976,016 B2
`(10) Patent No:
`a2) United States Patent
`Allison et al.
`(45) Date of Patent:
`Apr.13, 2021
`
`
`(54) ELEVATED STRUCTURE-MOUNTED
`LIGHTING SYSTEM
`
`(71) Applicant: C&M OILFIELD RENTALS, LLC,
`Cody, WY (US)
`
`33/00 (2013.01); F21W 2131/1005 (2013.01);
`F21W 2131/402 (2013.01); F21W2131/403
`(2013.01)
`
`(58) Field of Classification Search
`CPC eeeeessee F218 8/088; F21V 21/116; F21V 33/00
`See application file for complete search history.
`
`(72)
`
`Inventors: Joshua C. Allison, Cody, WY (US);
`Josh Haaland, Cody, WY (US); Jessica
`Ivanoff, Cody, WY (US)
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`5.272611 A
`8.814.221 B2
`
`12/1993 Lai
`8/2014 Grant
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`(73) Assignee: C&M OILFIELD RENTALS, LLC,
`Cody, WY (US)
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`US.C. 154(b) by 0 days.
`
`(*) Notice:
`
`(21) Appl. No.: 17/016,083
`
`(22)
`(65)
`
`Filed:
`
`Sep. 9, 2020
`Prior Publication Data
`US 2020/0408373 Al
`Dec. 31. 2020
`
`Related U.S. Application Data
`(63) Continuation-in-part of application No. 16/571,527,
`filed on Sep. 16, 2019, now Pat. No. 10,900,626,
`(Continued)
`
`CA
`CA
`
`3034206
`03096128
`
`3/2018
`10/2020
`(Continued)
`
`OTHER PUBLICATIONS
`Swivelpole Brochure; Swivelpole Product Catalogue NEC V2-4.
`Printed Mar. 2014, pp. 5-9.
`Primary Examiner — Anne M Hines
`(74) Attorney, Agent, or Firm — Morgan, Lewis &
`Bockius LLP
`ABSTRACT
`(57)
`An improved elevated structure-mounted lighting system is
`disclosed. The lighting system may be used on drilling rigs,
`or with other applications, including for drilling, production,
`refineries, frac sites, construction, and other industrial appli-
`cations that may use tower/mast
`type equipment. The
`improved elevated structure-mounted lighting system may
`accommodate any style or design of crown section or the
`derrick of a drilling rig and may be mounted on a pole or
`independent mountsystem.
`
`29 Claims, 18 Drawing Sheets
`
`
`
`(51)
`
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`(2006.01)
`
`Int. Cl.
`F2IV 21/116
`F21S 8/08
`F21V 33/00
`E21B 41/00
`F2IW 131/402
`F2IW 131/403
`F21W 131/10
`(52) U.S. Cl.
`CPC wees F218 8/088 (2013.01); £21B 41/00
`(2013.01); F21V 21/116 (2013.01); F21V
`
`oyoy"|
`|
`|
`| L230
`
`° |
`
`i
`
`
`
`
`Petitioner Ensign
`Exhibit 1001 - 1 of 24
`
`:Syaioc
`
`y1 a
`ne oe ce ne com Lt nsne
`rt
`|
`
`I i
`
`—H
`
`Petitioner Ensign
`Exhibit 1001 - 1 of 24
`
`

`

`US 10,976,016 B2
`
`Page 2
`
`Related U.S. Application Data
`—
`.
`which is a continuation of application No. 16/138,
`723, filed on Sep. 21, 2018, now Pat. No. 10,473,282,
`which is a continuation-in-part of application No.
`16/009,032, filed on Jun. 14, 2018, now Pat. No.
`10.711.961.
`se
`(60) Provisional application No. 62/643,663, filed on Mar.
`15, 2018.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`9,316,390 B2
`D757,343 S
`9,534,626 B2
`9,945,143 B2
`10,125,935 B2
`10,145,544 B2
`
`4/2016 Gowanlocketal.
`5/2016 Dupuiset al.
`1/2017 Walton et al.
`4/2018 Pannekoeket al.
`11/2018 Gowanlock etal.
`12/2018 Gowanlocketal.
`
`10,392,826 B2
`10,473,282 B2
`10,598,359 B2
`2005/0184207 Al
`2012/0217897 Al
`2013/0135848 Al
`2015/0184840 A1l*
`
`2016/0109079 Al
`2017/0023195 Al
`2018/0010748 Al
`2018/0163956 Al
`2018/0187873 Al
`2019/0242218 Al
`
`8/2019 Pannekoek et al.
`11/2019 Allisonet al.
`3/2020 Pannekoeketal.
`8/2005 Bertram,III
`8/2012 Gordinetal.
`5/2013 Chrysanthous
`7/2015 Gowanlock............. F21V 33/00
`362/249.1
`
`4/2016 McKinleyetal.
`1/2017 Gowanlock
`1/2018 Gowanlock
`6/2018 Gowanlock
`7/2018 Carroll
`8/2019 Gowanlock
`
`
`FOREIGN PATENT DOCUMENTS
`
`CN
`WO
`
`108240588
`2019191843
`
`7/2018
`10/2019
`
`* cited by examiner
`
`Petitioner Ensign
`Exhibit 1001 - 2 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 2 of 24
`
`

`

`U.S. Patent
`
`Apr. 13,2021
`
`Sheet 1 of 18
`
`US 10,976,016 B2
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`Petitioner Ensign
`Exhibit 1001 - 3 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 3 of 24
`
`

`

`U.S. Patent
`
`Apr. 13,2021
`
`Sheet 2 of 18
`
`US 10,976,016 B2
`
`210
`
`200
`
`220
`
`230
`
`205
`
`
`
`CROWNDECK 110
`
` EXISTING
`
`
`
`Petitioner Ensign
`Exhibit 1001 - 4 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 4 of 24
`
`

`

`U.S. Patent
`
`Apr. 13, 2021
`
`Sheet 3 of 18
`
`US 10,976,016 B2
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`Petitioner Ensign
`Exhibit 1001 - 5 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 5 of 24
`
`
`

`

`Apr. 13,2021
`
`Sheet 4 of 18
`
`U.S. Patent
`
`US 10,976,016 B2
`
`
`
`Petitioner Ensign
`Exhibit 1001 - 6 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 6 of 24
`
`

`

`U.S. Patent
`
`Apr. 13,2021
`
`US 10,976,016 B2
`
`Sheet 5 of 18
`
`
`
`
`
`FIG. 6
`
`Petitioner Ensign
`Exhibit 1001 - 7 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 7 of 24
`
`

`

`U.S. Patent
`
`Apr. 13,2021
`
`Sheet 6 of 18
`
`US 10,976,016 B2
`
`248
`
`KeeDApLLAQ0Z|
`
`400
`
`402
`252
`
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`334
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`330
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`aolaPN 380
`372
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`310
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`244
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`FIG. 7A
`
`Petitioner Ensign
`Exhibit 1001 - 8 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 8 of 24
`
`

`

`U.S. Patent
`
`Apr. 13,2021.
`
`Sheet 7 of 18
`
`US 10,976,016 B2
`
`248
`
`322
`
`Petitioner Ensign
`Exhibit 1001 - 9 of 24
`
`
`350 |ag
`
`bor
`
`
` FIG. 7B
`
`mel
`
`Petitioner Ensign
`Exhibit 1001 - 9 of 24
`
`

`

`U.S. Patent
`
`Apr. 13, 2021
`
`Sheet 8 of 18
`
`US 10,976,016 B2
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`
`
`
`
`FIG. 8
`
`Petitioner Ensign
`Exhibit 1001 - 10 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 10 of 24
`
`

`

`U.S. Patent
`
`Apr. 13, 2021
`
`Sheet 9 of 18
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`US 10,976,016 B2
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`
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`Petitioner Ensi
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`Petitioner Ensign
`Exhibit 1001 - 11 of 24
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`

`

`U.S. Patent
`
`Apr. 13,2021
`
`Sheet 10 of 18
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`US 10,976,016 B2
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`
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`Exhibit 1001 - 12 of 24
`
`n
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`Petitioner Ensign
`Exhibit 1001 - 12 of 24
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`

`

`U.S. Patent
`
`Apr. 13, 2021
`
`Sheet 11 of 18
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`
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`
`
`
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`
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`Petitioner Ensign
`
`Petitioner Ensign
`Exhibit 1001 - 13 of 24
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`

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`Petitioner Ensign
`Exhibit 1001 - 14 of 24
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`

`

`
`
`Petitioner Ensign
`
`Petitioner Ensign
`Exhibit 1001 - 15 of 24
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`

`

`
`
`Petitioner Ensign
`Exhibit 1001 - 16 of 24
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`

`

`U.S. Patent
`
`Apr. 13,2021
`
`Sheet 15 of 18
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`US 10,976,016 B2
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` Ze
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`Petitioner Ensign
`Exhibit 1001 - 17 of 24
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`Petitioner Ensign
`Exhibit 1001 - 17 of 24
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`

`

`Petitioner Ensign
`
`Petitioner Ensign
`Exhibit 1001 - 18 of 24
`
`

`

`
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`Petitioner Ensign
`Exhibit 1001 - 19 of 24
`
`

`

`
`
`Petitioner Ensign
`Exhibit 1001 - 20 of 24
`
`

`

`US 10,976,016 B2
`
`1
`ELEVATED STRUCTURE-MOUNTED
`LIGHTING SYSTEM
`
`TECHNICAL FIELD
`
`BACKGROUND
`
`10
`
`2
`FIG.3 illustrates an elevation viewof three embodiments
`of the improved elevated structure-mountedlighting system
`that are depicted relative to a crown deck.
`FIGS. 4A and 4B are enlarged views of two embodiments
`of a light fixture and cap of a light unit of the improved
`elevated structure-mounted lighting system.
`The present application relates to lighting systems, and
`FIG. 5 is an enlarged view of an embodimentof a light
`more particularly, to lighting systems that may be used for
`fixture and a cap ofalight unit illustrating different positions
`a drilling application.
`of the light fixture.
`FIG.6 is a side view of an embodimentof a light fixture
`mounting pole.
`FIG. 7A is a side view of the embodiment of FIG. 6 with
`a light fixture that is attached to rails.
`FIG. 7B is a side view of the embodiment with a single
`mounting plate.
`FIG. 8 is a perspective view of the embodiment of FIG.
`
`15
`
`6.
`
`Lighting systems for drilling rigs and their surrounding
`areas are critical to ensure continuous and safe operation of
`well sites. To ensure even and effective lighting of the well
`site, lighting systems have previously been installed on the
`uppermost portion of the drilling rig, also referred to as the
`“crown”of the rig. Prior art crown-mounted lighting sys-
`FIGS. 9A-9F show various configurations of light fixture
`tems developedfor oil rigs are limited in several ways. Their
`mounting embodiments onarig.
`designs are complicated and designed for specific rigs orrig
`20
`FIGS. 10A-10D show various configurations of light
`types. Typically, once they are designed for a particularrig
`fixture mounting embodiments on the crown deck ofa rig.
`or a particular type of rig, the lighting systems designs are
`limited and are not able to be adapted for other uses.
`Prior art
`lighting systems for drilling rigs are fixed,
`monolithic structures that are typically crown or frame
`systems, with a single size and layout accommodating one
`type of light and rig. Because they are a single structural
`unit, they are heavy andtypically require cranes along with
`multiple workers for installation, removal, and adjustments.
`A typical rig lighting frame system may require between 6
`and 12 hours for installation. Further, before a derrick can be
`moved, the lighting systems must be removed—again with
`all of the necessary equipment and personnel—anda similar
`amount of time may be required for uninstallation. These
`installation and uninstallation times extend the time needed
`between rig deployments. Due to the high cost of operating
`a rig, any such delay is extremely inefficient for the operator
`of a wellsite. These factors also increase the time required to
`be spent on maintaining these systems, which also increases
`safety risk.
`
`FIG.1 illustrates a priorart lighting system 100. The prior
`art lighting system is built from a single frame 120 which
`includes multiple framelights 130. The frame lights 130 are
`rigidly fixed onto the frame 120 and cannot be adjusted or
`repositioned. The frame 120 includes the electrical connec-
`tions for the lights. The frame 120 may beinstalled on the
`crown 110, or top, of a drilling rig such that the ground
`around the drilling rig is illuminated whenin use.
`FIG. 2 shows a three-dimensional isometric view and
`FIG. 3 shows an elevation view of three embodiments of the
`improved elevated structure-mounted lighting system 200
`that are depicted relative to a crown deck. The embodiments
`of the lighting system 200 may be mounted on the crown
`deck of a drilling rig or on other elements of a frame
`structure. The lighting system 200 is lightweight in design
`and may be manufactured using any type of metal, including
`aluminum, steel, carbon, hot roll, etc. The frame structure
`maybe hollow to reduce weight. The lighting system is also
`modular, which allows it to be assembled onsite without the
`use of heavy equipment, cranes, harnesses, supports, cables,
`etc. This reduces the risk of accidents andthe time and costs
`associated with the same.
`In an embodiment, a pole-
`mounted design may be set up by two people in under one
`hour. The system may accommodate a variety of different
`light types, with differing luminosities and power consump-
`tion, that may be selected based on the particular applica-
`tion. Variations of light types may include combustion-proof
`and/or LEDlights.
`Thelighting system 200 is modular and assembled using
`multiple standalone pieces that may be configured to differ-
`ent structures. Three lighting unit embodiments from FIGS.
`Embodiments of the present invention are described with
`2 and 3 are shown in an I-shape 210, T-shape 220, and
`reference to the following figures. The same numbers are
`L-shape 230, but this is not limiting and other configurations
`used throughout the figures to reference like features and
`or modifications may be used, due in part to the modular
`components. Various embodiments may utilize elements
`nature of the system. There is no master frame or master
`and/or components other than those illustrated in the draw-
`support structure, which allows for configurability and cus-
`ings, and some elements and/or components may not be
`tomization.
`present in various embodiments. Elements and/or compo-
`As shownin FIG.3, the light units 210, 220, and 230 may
`nents in the figures are not necessarily drawnto scale.
`include a mounting pole 240, a bracket for a top rail 242, a
`FIG. 1 illustrates a prior art crown-mounted frame-based
`
`lighting system. bracket for a bottom rail 244, a cap 246, andalight fixture
`65
`FIG. 2 shows a three-dimensional isometric view of three
`248. The bracket for a top rail 242 and bracket for a bottom
`embodiments of the improved elevated structure-mounted
`rail 244 maybe usedto attach the light mounting pole 240
`lighting system that are depicted relative to a crown deck.
`to rails 205 of a crown deck of a drilling rig using U-shaped
`Petitioner Ensign
`Exhibit 1001 - 21 of 24
`
`DETAILED DESCRIPTION
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`SUMMARY
`
`An improved elevated structure-mounted lighting system
`is disclosed. In addition to being used on rigs, embodiments
`of the lighting system may be used with different applica-
`tions, including for drilling, production,refineries, frac sites,
`construction, and other industrial applications that may use
`tower/mast type equipment. The improved elevated struc-
`ture-mounted lighting system may accommodate anystyle
`or design of crown section of a drilling rig and may be
`mounted on a pole or independent mount system.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Petitioner Ensign
`Exhibit 1001 - 21 of 24
`
`

`

`US 10,976,016 B2
`
`
`
`3
`bolts or straps, as shown in FIG, 2. The straps are wrench-
`type straps that may be made outof a plastic composite. In
`another embodiment, the mounting pole 240 may be welded
`directly to the drilling rig crown or other structure.
`In the alternative embodiment shownin FIG, 6, mounting
`pole 240 may be attached to the crown deck or other
`structure using brackets 300 and 310 that attach to toprail
`242 and bottom rail 246 respectively.
`In this particular
`embodiment, bracket 300 comprises a top mount plate 320
`and a top rail clamp 330, while bracket 310 comprises
`bottom mountplate 360 and clamp plate 370. One benefit of
`this alternative embodiment is allowing the use of shorter
`mounting poles, which thereby reducesthe overall weight of
`the system. As shown more clearly in FIG. 7A, top mount
`plate 320 includesa vertical portion 322 that is substantially
`parallel to the central axis of mounting pole 240 and a
`horizontal portion 324 that is substantially parallel to the top
`surface of top rail 242. Similarly, top rail clamp 330 includes
`a vertical portion 332 that is substantially parallel to the
`central axis of mounting pole 240 and a horizontal portion
`334 that is substantially parallel to the top surfaceoftop rail
`242. The horizontal portions of top mount plate 320 and top
`rail clamp 330 are connected together, as for example by one
`or more bolts, as shown in FIG. 7. Alternatively, as shown
`in FIG. 7A, top mountplate 320 and top rail clamp 330 may
`be combinedinto a single component that hooks over the top
`of top rail 242.
`Mounting pole 240 is held in place and attachedto top rail
`242 by the use of one or more bolts 340, whichare inserted
`through both top mount plate 320 and top rail clamp 330. In
`the embodiment of FIG. 7A with no separate top rail clamp,
`bolt(s) 340 are inserted through both vertical portions of top
`mountplate 320.
`Mounting pole 240 may be further held in position using
`one or more tube clamps 350, whichare bolted or otherwise
`connected to top mountplate 320 and/or bottom mountplate
`360.
`Also as shown in FIG. 7A, bottom mount plate 360
`includes a vertical portion 362 that is substantially parallel
`to the central axis of mounting pole 240. Optionally (but not
`shown), bottom mount plate 360 may also include a hori-
`zontal portion that is substantially parallel to the bottom of
`bottom rail 244. Clamp plate 370 also includes a vertical
`portion 372 that is substantially parallel to the central axis of
`mounting pole 240. Also, optionally (but not shown), clamp
`plate 360 may include a horizontal portion that is substan-
`tially parallel to the bottom of bottom rail 244. Alternatively,
`as shown in FIG. 7B, bottom mount plate 360 and clamp
`plate 370 may be combinedinto a single component336 that
`hooks over the bottom of bottom rail 242. In FIG. 7B, bolt
`340 maybe optional.
`Mounting pole 240 is held in place and attached to bottom
`rail 244 by the use of one or more bolts 380, which are
`inserted through both bottom mount plate 360 and clamp
`plate 370. In the embodiment of FIG. 7A with no separate
`clamp plate, bolt(s) 380 are inserted through both vertical
`portions of bottom mountplate 360. Mounting pole 240 may
`be further held in position using tube clamp 350, whichis
`also bolted or otherwise connected to mountplate 320.
`As shown in FIG. 6, top mount plate 320 and bottom
`mountplate 360 are also connected to each other, using one
`or more bolts 390 or other fastening devices, providing
`further stability and for this alternative embodiment.
`In addition, top mount plate 320 and bottom mountplate
`360 maybe configured with one or more vertically extend-
`ing apertures 392 (as shown in FIG. 8), allowing the two
`mountplates to be movedvertically in relation to each other,
`
`4
`while still providing the ability to insert bolt(s) 390 or other
`fastening devices through both mountplates. The vertically
`extending apertures 392 thus allowthis alternative embodi-
`ment to be used on crown decks or other structures with a
`wide range of different dimension and configurations.
`The light fixture 248 connects structurally and electrically
`to the cap 246, which houses wiring to accommodate any
`light fixture 248 that may be attached. The shape or con-
`figuration of cap 246 is not limited to that reflected in the
`figures, and other designs may be used aslongasthe capis
`capable of being coupled to the light fixture 248. For
`example, cap 246 may be a metal bracket onto which the
`light fixture 248 is attached. Referring to FIGS. 4A and 4B,
`the light fixture 248 may be bolted to the cap 246, but is
`preferably connected to the cap using a pin-based engage-
`ment. The pins 250 may be removable. Oncethe light fixture
`248 is engaged with the cap 246 such that pinholes 252 are
`aligned, one or more pins 250 may be inserted to securely
`connectthe light fixture 248 to the cap 246. Because the pins
`250 are removable, the light fixture 248 may be discon-
`nected and removed from the cap 246 by removing the pins
`250. The light fixture 248 and cap 246 are preferably
`structured so that the light fixture 248 may be engaged with
`the cap 246 to face outward (as shown in FIG. 4A)or to face
`inward (as shown in FIG. 5). This may be accomplished by
`aligning the pinholes 252 in at least a first position or in a
`second position. The light fixture 248 may be configured in
`the outward position for use and installed in the inward
`position for transport.
`Based on the design, more than two positions may be
`contemplated. For example, as shown in FIG. 7A, mounting
`pole 240 may be configured with a plurality of pinholes 252.
`In this embodiment, where mounting pole 240 is cylindrical,
`pinholes 252 mayberadially spaced around the circumfer-
`ence of mounting pole 240. In addition,light fixture 248 may
`be connected to cap 246 by the use oflight bracket 400. In
`this embodiment, as shown in FIG. 7A, light bracket 400
`comprises a generally cylindrical portion 402, which
`extends telescopically into at
`least the upper portion of
`mounting pole 240. In addition, cylindrical portion 402 is
`configured with one or more pinholes 404 which are con-
`figured to be aligned with the one or more pinholes 252 on
`mounting pole 240. In this way, pin(s) 250 may be used to
`maintain light fixture 248 in a plurality of different positions
`simply by removing pin 250 rotating the light bracket 400
`until pinhole 404 aligns with a different pinhole on mounting
`pole 240, and reinserting pin 250 in the new position. While
`the cap 246 andlightfixture 248 are preferably proximateto
`the brackets that couplethe light unit 210, 220, or 230 to the
`structure, an extension may be used betweenthe cap 246 and
`the light fixture 248 to extend the light fixture 248 away
`from the structure to which the light unit 210, 220, or 230 is
`mounted.
`Safety cables connected betweenthe light fixture 248 and
`cap 246 may be used as a backup in the event that pins 250
`back out or are sheared during an extreme weather condi-
`tion.
`
`20
`
`25
`
`40
`
`45
`
`60
`
`65
`
`Generally, the light units 210, 220, and 230 have a low
`profile to minimize the wind shear forces that may be
`experienced bythe light units at the top of a structure (such
`as a rig) to which they are mounted. In a preferred embodi-
`ment, as shown in FIGS. 2-8, the light units 210, 220, and
`230 will extend above the crown deck and handrails(s) only
`as far as reasonably necessary for light fixture 248 to be
`configured such thatit is able to illuminate the groundin the
`area surrounding the structure upon which the light unit is
`mounted.
`
`Petitioner Ensign
`Exhibit 1001 - 22 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 22 of 24
`
`

`

`US 10,976,016 B2
`
`5
`As shownin FIGS. 2-8,it is also preferable that mounting
`pole 240 be formed of a single unitary piece, rather than
`multiple separate portions that are joined together using
`bolts, screws, hinges, or other similar connections. Such a
`design naturally contributes to the structural stability of the
`light unit.
`With prior art lighting systems, when a square frame is
`mounted, the lights are also fixed and cannot be moved as
`they are attached to the frame as a single unit. In contrast, in
`the improved elevated structure-mounted lighting system,
`each light may be mounted on a standalone base, and does
`not haveto be attached to a master frame. Referring back to
`FIGS. 2 and 3, multiple light units 210, 220, and 230 may
`be installed on a crown in different configurations.
`Accordingly, the lights may be individually shifted up,
`down,left, or right. Based on the location of a light unit 210,
`220, or 230, if more surface area is required to be lit on a
`particular side, the lights may be configured and directed in
`that direction, or the light pole may be adjusted to achieve
`optimal surface lighting. Individual LED bulbs may be
`angled in a way to produce the greatest amount of light
`without dissipation. The lights or LED bulbs may be used
`with visors that are able to direct light in various directions.
`In an embodiment, efficient lights allowthe lighting system
`to be run from 120V or 240V. The lights may come with
`dimmer, solar, and/or sensor options. Using sensors, the
`lights may be configured to illuminate when a particular
`ambient light threshold is reached, such as at dusk, dawn, or
`in overcast conditions. The lights may also utilize dimmer
`controllers, such that the lumen output may be adjusted to
`accommodate different conditions or configurations. Using
`both dimmable lights and sensors, the lights may be con-
`figured to gradually increase lumen output as ambient light
`decreases, which would promote efficient power consump-
`tion. The lights may also be configured for remote operation,
`such that the lights could be turned off or on using a wired
`or wireless controller from the base of the rig deck. As
`explained in further detail below, the lights may also be
`powered using a backupbattery, and the backup battery may
`be charged using solar power. These factors allow for
`lighting to be achieved moreefficiently than prior art light-
`ing systems.
`As one of skill in the art would understand from reading
`the foregoing description, it is not necessary that the light
`fixtures 248 be attached to the rig or other structure using
`mounting poles that have the particular configuration shown
`in FIGS. 2-8. Consistent with the modular design that is
`central to the present invention, light fixtures may be con-
`nected to the structure using mounting brackets or other
`similar means of attachment.
`For example, as shown in the embodiments in FIGS.
`9A-9F,
`the light fixtures 248 may be installed onto the
`derrick or mast structure of a rig (FIG. 9E), or they may be
`installed on the top (FIG. 9F), side (FIGS. 9A-9C), or
`bottom (FIG. 9D) of the crown deck. As shownin FIG. 9A,
`the light fixture may be mounted onto a rig using a rig
`mounting bracket that directly bolts onto the side of the
`crown deck. The light fixture may be mounted onto a light
`fixture bracket that structurally connects to the rig mounting
`bracket. As shown in FIGS. 9B and 9C,the rig mounting
`bracket may be mountedto the side of the crown deck using
`one or more magnets. Rare earth magnets, such as neo-
`dymium magnets, are able to exert a significant magnetic
`pull force over even relatively small surface areas. For
`example,
`two four-inch diameter neodymium magnets
`would be rated for up to 2,600 Ibs of pull force.
`
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`As shown in FIGS. 10A-10D, various other configura-
`tions of rig mounting brackets may be used to connectlight
`fixtures 248 to the handrail of the crown deck. FIG. 10A
`shows a mounting pole secured to the top of a crown deck
`of a rig and also secured to two handrails using U-shaped
`bolts. FIG, 10B shows a mounting bracket attached to a
`single square handrail using two U-shaped bolts. FIGS. 10C
`and D show two different examples of a rig mounting
`bracket that spans two handrails and uses multiple U-shaped
`bolts. The rig mounting brackets may be secured to the rig
`structure using other configurations of bolts, and, as men-
`tioned above, may also be welded directly to the rig struc-
`ture. Rig mounting brackets that span multiple rig structural
`elements, such as the ones shown in FIGS. 10B and C that
`span two handrails, may be able to more easily support
`multiple loads, including multiple light fixtures 248, or a
`combination of light fixtures 248 and solar panels. To
`accommodate various configurations of ngs and illumina-
`tion requirements, the light fixtures 248 may be mounted to
`the structure using any combination of the mounting
`examples above.
`Metal safety nets may also be affixed to the crown below
`the light units 210, 220, and 230. In additional to its modular
`framedesign,the lighting system 200 may use consistent nut
`and bolt sizes, which allows flexibility and interoperability
`in its structural design and assembly.
`The modular nature of the improved elevated structure-
`mounted lighting system also allowsforit to be serviced or
`adjusted whileit is erect and installed. There is a single cable
`to connect to a power source from crown to ground. At the
`lighting junction box, 12 quarter tum Appletons may be
`used. Woodhead plugs mayalsobe used on the junction box.
`Further, the improved elevated structure-mounted lighting
`system does not have to be removedor taken down whenthe
`derrick or other applications are being transported or moved,
`which is allowed because the cords may be disconnected,
`rather than removed, during transport. Once transport is
`complete, the cords may be reconnected. Other features,
`such as an explosion-proofcontrol panel on the ground with
`power switches may be used. As noted above, due to the
`high costs of rig operation, reducing time for installation and
`maintenance and improving safety are significant factors to
`reducing operation costs.
`In an embodiment, the light fixtures 248 may bepartially
`or completely powered by a solar array. A solar array may
`include solar panels, a battery unit, a step converter, and a
`powerinverter. The solar panels capture solar energy and
`generate electricity that can be either used to powerlight
`fixtures 248 (and/or other equipment) or stored in the battery
`unit.
`In a common configuration,
`the light fixtures 248
`would operate at night and draw electricity from the battery
`unit, using energy collected by the solar panels during the
`day and stored in the battery unit. When ambientlightis low,
`such as during dawn, dusk, or in overcast conditions, or
`whenadditional illumination is needed, the light fixtures 248
`may operate concurrently while solar energy is being col-
`lected. In instances in whichlight fixtures 248 require direct
`current (DC), a DC-DCstep converter may be used to match
`the correct voltage input needed bythe light fixtures 248. In
`instances in which alternating current (AC) is needed, a
`powerinverter could be used to convert DC power, such as
`the output from the solar panels or the output from the
`battery unit, to usable AC, which may be used by light
`fixtures 248 or other equipment. Various combinations of
`battery units, step converters, and power inverters may be
`used to accommodate different configurations and require-
`ments of the lighting system 200.
`
`Petitioner Ensign
`Exhibit 1001 - 23 of 24
`
`Petitioner Ensign
`Exhibit 1001 - 23 of 24
`
`

`

`US 10,976,016 B2
`
`7
`In an embodiment,the solar panels may be mounted to the
`handrails of the crown deckofa drilling rig. The solar panels
`may be mounted on their own or share mounting hardware
`with the light units 210. In that sense, one or more solar
`panels may be mounted to the mounting pole 240, to the top
`rail (242) or bottom rail (244) brackets, or to another point
`on mounting hardware for the light unit. Each solar panel
`could be mounted in a position that would optimize solar
`collection. In an embodiment, the solar panels mounted such
`that they may be moved into more than one position. One
`position may preferably serve as an operating position,
`while another position may preferably serve as a travel
`position. The solar panels may be configured in the operat-
`ing position for use andin the travel position for transport or
`storage. In one embodiment, the solar panels may be sepa-
`rately mounted on other portions of the rig or on other
`structures.
`
`Many modifications and other implementations beyond
`those set forth herein will be apparent having the benefit of
`the teachings presentedin the foregoing descriptions andthe
`associated drawings. Therefore, it is to be understood that
`the systems and methods described herein are not to be
`limited to the specific implementations disclosed and that
`modifications and other implementations are intended to be
`included within the scope ofthe appended claims. Although
`specific terms are employed herein,
`they are used in a
`generic and descriptive sense and not for purposes of
`limitation.
`
`the
`
`The invention claimed is:
`1. A modular lighting system mounted on a rig,
`modular lighting system comprising:
`a plurality of light units, each light unit separately
`attached to a crown deck ofthe rig, and eachlight unit
`comprising:
`a mounting pole;
`a light fixture comprising one or more lights; and
`a bracket configured to attach the mountingpole to the
`crown deck oftherig.
`2. The lighting system of claim 1, wherein the bracket is
`connected to the crown deck of the rig using bolts.
`3. The lighting system of claim 1, wherein the bracketis
`connected to the crown deck of the rig using a magnet.
`4. The lighting system of claim 3, wherein the magnetis
`a neodymium magnet.
`5. The lighting system of claim 1, wherein the bracketis
`configured to be connectedto an underside of the base ofthe
`crown deck of the rig.
`6. The lighting system of claim 1, wherein the lighting
`system further comprises a plurality of solar panels.
`7. Thelighting system of claim 6, wherein one or more of
`the plurality of solar panels is configured to be connected to
`either the base or the side of the crown deck ofthe rig.
`8. The lighting system of claim 6, wherein the lighting
`system further comprises a battery.
`9. The lighting system of claim 6, wherein one or more of
`the plurality of solar panels is structurally coupled to either
`the base or the side of the crown deck ofthe rig in a first
`position or a second position.
`10. The lighting system of claim 9, wherein when the one
`or moreofthe plurality of solar panels is in thefirst position,
`the one or more of the plurality of solar panels are oriented
`in an operational position.
`11. The lighting system of claim 10, wherein when the one
`or more of the plurality of solar panels is in the second
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`position,the one or moreofthe plurality of solar panels are
`oriented in a transport position.
`12. The lighting system of claim 6, wherein the lighting
`system further comprises a powerinverter.
`13. The lighting system of claim 6, wherein the lighting
`system further comprises a step converter.
`14. The lighting system of claim 1, wherein the rig is a
`drilling rig.
`15. The lighting system of claim 1, wherein the bracket is
`welded to the crown deck of the rig.
`16. The lighting system of claim 1, wherein each light unit
`is directly attached to the crown deck of the rig.
`17. A method of illuminating a wellsite, comprising the
`steps of:
`attaching a plurality of mounting poles to a crown deck of
`a rig, wherein each ofthe plurality of mounting poles
`is separately attached to the crown deck;
`mountinga plurality of lights to the plurality of mounting
`poles, wherein eachofthe plurality of mounting poles
`supports at least one ofthe plurality of lights, and each
`of the plurality of lights is mounted to only one ofthe
`plurality of mounting poles; and
`illuminating the wellsite using the plurality of lights.
`18. The method of claim 17, further comprising individu-
`ally adjusting each of the plurality of lights.
`19. The method of clai