Patent Grant
10745978
Embodiments of the present disclosure generally relate to equipment and methods for coupling a top drive to one or more tools. The coupling may transfer both axial load and torque bi-directionally from the top drive to the one or more tools.
A wellbore is formed to access hydrocarbon-bearing formations (e.g., crude oil and/or natural gas) or for geothermal power generation by the use of drilling. Drilling is accomplished by utilizing a drill bit that is mounted on the end of a tool string. To drill within the wellbore to a predetermined depth, the tool string is often rotated by a top drive on a drilling rig. After drilling to a predetermined depth, the tool string and drill bit are removed, and a string of casing is lowered into the wellbore. Well construction and completion operations may then be conducted.
During drilling and well construction/completion, various tools are used which have to be attached to the top drive. The process of changing tools is very time consuming and dangerous, requiring personnel to work at heights. The attachments between the tools and the top drive typically include mechanical, electrical, optical, hydraulic, and/or pneumatic connections, conveying torque, load, data, signals, and/or power.
Typically, sections of a tool string are connected together with threaded connections. Such threaded connections are capable of transferring load. Right-hand (RH) threaded connections are also capable of transferring RH torque. However, application of left-hand (LH) torque to a tool string with RH threaded connections (and vice versa) risks breaking the string. Methods have been employed to obtain bi-directional torque holding capabilities for connections. Some examples of these bi-directional setting devices include thread locking mechanisms for saver subs, hydraulic locking rings, set screws, jam nuts, lock washers, keys, cross/thru-bolting, lock wires, clutches and thread locking compounds. However, these solutions have shortcomings. For example, many of the methods used to obtain bi-directional torque capabilities are limited by friction between component surfaces or compounds that typically result in a relative low torque resistant connection. Locking rings may provide only limited torque resistance, and it may be difficult to fully monitor any problem due to limited accessibility and location. For applications that require high bi-directional torque capabilities, only positive locking methods such as keys, clutches or cross/through-bolting are typically effective. Further, some high bi-directional torque connections require both turning and milling operations to manufacture, which increase the cost of the connection over just a turning operation required to manufacture a simple male-to-female threaded connection. Some high bi-directional torque connections also require significant additional components as compared to a simple male-to-female threaded connection, which adds to the cost.
Safer, faster, more reliable, and more efficient connections that are capable of conveying load, data, signals, power and/or bi-directional torque between the tool string and the top drive are needed.
The present disclosure generally relates to equipment and methods for coupling a top drive to one or more tools. The coupling may transfer both axial load and torque bi-directionally from the top drive to the one or more tools.
A downhole tool coupling system comprising a drive stem, a sleeve, and a plurality of locking clamps. The sleeve is longitudinally movable relative to the drive stem. The locking clamps are at least partially encompassed by the sleeve. The locking clamps are rotatable between an open position and a locked position. The sleeve is oriented relative to the locking clamps to rotate and radially move the locking clamps from the open position to the locked position as the sleeve moves longitudinally from a first position to a second position. Each locking clamp has an interior recessed region configured to clamp the drive stem to a tool stem when in the locked position.
A downhole tool coupling system comprising a drive stem, a sleeve, and a plurality of locking clamps. The sleeve is longitudinally movable relative to the drive stem. The locking clamps are at least partially encompassed by the sleeve. The locking clamps are radially movable between an open position and a locked position. The sleeve is oriented relative to the locking clamps to radially move the locking clamps from the open position to the locked position as the sleeve moves longitudinally from a first position to a second position. Each locking clamp has an interior recessed region configured to clamp the drive stem to a tool stem when in the locked position.
A method for connecting a drive stem and a tool stem includes moving a sleeve longitudinally relative to the drive stem from a first position to a second position, moving a plurality of locking clamps radially between an open position and a locked position as the sleeve moves from the first position to the second position, the plurality of locking clamps at least partially encompassed by the sleeve, and engaging the tool stem with the plurality of locking clamps, thereby connecting the drive stem to the tool stem in the locked position.
A method for connecting a drive stem and a tool stem includes moving a sleeve longitudinally relative to the drive stem from a first position to a second position, rotating a plurality of locking clamps radially between an open position and a locked position as the sleeve moves from the first position to the second position, the plurality of locking clamps at least partially encompassed by the sleeve, and engaging the tool stem with the plurality of locking clamps, thereby connecting the drive stem to the tool stem in the locked position.
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.
In the description of the representative embodiments of the invention, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. In general, “above”, “upper”, “upward” and similar terms refer to a direction toward the earth's surface along a longitudinal axis of a wellbore, and “below”, “lower”, “downward” and similar terms refer to a direction away from the earth's surface along the longitudinal axis of the wellbore.
The present disclosure provides equipment and methods for coupling a top drive to one or more downhole tools. The downhole tool coupling system may transfer torque bi-directionally from the top drive to the one or more tools. The coupling system may provide mechanical, electrical, optical, hydraulic, and/or pneumatic connections. The coupling system may convey torque, load, data, signals, and/or power. For example, axial loads of tool strings may be expected to be several hundred tons, up to, including, and sometimes surpassing 750 tons. Required torque transmission may be tens of thousands of foot-pounds, up to, including, and sometimes surpassing 100 thousand foot-pounds. Embodiments disclosed herein may provide axial connection integrity, capable of supporting high axial loads, good sealability, resistance to bending, high flow rates, and high flow pressures.
A downhole tool coupling system 8 is configured to connect the tool string 2 to the top drive 4 via a drive stem 6. In this manner, the top drive 4 supports the axial load of the tool string 2. The drive stem 6 may directly connect to the top drive 4, for example, by threading into a quill of the top drive. Alternatively, the drive stem 6 may indirectly connect to the top drive 4, for example, by connecting to an adaptor that directly connects to the quill of the top drive. The downhole tool coupling system 8, discussed in more detail below, provides for safer, faster, more reliable, and more efficient connections that are capable of conveying load, data, signals, power and/or bi-directional torque between the tool string and the top drive are needed.
In one embodiment of the present disclosure shown in
Each locking clamp 106 may be substantially similar in shape. In total, the downhole tool coupling system 100 may include ten locking clamps. It is to be understood, however, that the downhole tool coupling system 100 may include more or less locking clamps than ten. As best seen in
As best seen in
The sleeve 104 may be longitudinally movable relative to the drive stem 102 and the exterior housing 108. As best seen in
As seen in
As seen in
While the locking clamps 106 are in the open position, the bottom surface of the shoulders 130 of the drive stem 102 are brought into engagement with the top surface of the shoulders 109 of the tool stem 103, as seen in
After the locking clamps 106 are rotated to the intermediate position, further downward movement of the sleeve 104 to the second or lower position moves the locking clamps 106 radially inward because of the tapered inner contour of the sleeve 104 to the locked position, as can be seen in
As best seen in
To unclamp and release the tool stem 103 from the drive stem 102, the actuator 110 can be actuated to adjust the sleeve 104 from the second or lower position to the first or upper position. As the sleeve 104 adjusts from the second or lower position towards the first or upper position, the preload force is eliminated and the locking clamps 106 move radially outward. As the sleeve 104 continues to move upward, an upper portion of the sleeve engages the upper exterior shoulder surface 118 to thereby cause the locking clamps 106 to rotate to the open position. More specifically, as the sleeve 104 adjusts from the second or lower position to the first or upper position, the upper edge 132 of each locking clamp 106 pivots about the ridge 132 of the drive stem 102 until being located in the open position, as can be seen in
After the drive stem 102 is disconnected from the tool stem 103, the drive stem 102 can be moved away from the tool stem 103 such that the shoulders 130 of the drive stem 102 are no longer adjacent the shoulders 109 of the tool stem 103, as seen in
Another embodiment of the present disclosure is shown in
However, unlike the embodiment shown in
The actuator 208 includes a protrusion 212 located between an upper stop 214 and a lower stop 216 of the actuator adapter 210. The actuator adapter 210 is rigidly connected to the tool stem 202 such that the lower stop 216 is located above a notched region of the tool stem 202. The actuator 208 may be powered electrically, hydraulically, or pneumatically. As seen in
As seen in
While the locking clamps 206 are in the open position, a bottom surface of shoulders of the drive stem 202 are brought into engagement with the top surface of shoulders of the tool stem 203, as seen in
After the locking clamps 206 are rotated to the intermediate position, further downward movement of the sleeve 204 to the second or lower position moves the locking clamps 206 radially inward because of the tapered inner contour of the sleeve 204 to the locked position, as can be seen in
To unclamp and release the tool stem 203 from the drive stem 202, the actuator 210 can be actuated to adjust the sleeve 204 from the second or lower position to the first or upper position. As the sleeve 204 adjusts from the second or lower position towards the first or upper position, the preload force is eliminated and the locking clamps 206 move radially outward. As the sleeve 204 continues to move upward, an upper portion of the sleeve engages an upper exterior shoulder surface of the locking clamps 206 to thereby cause the locking clamps 206 to rotate to the open position. More specifically, as the sleeve 204 adjusts from the second or lower position to the first or upper position, the upper edge of each locking clamp 206 pivots about the ridge of the drive stem 202 until being located in the open position, as can be seen in
After the drive stem 202 is disconnected from the tool stem 203, the drive stem 202 can be moved away from the tool stem 203 such that the shoulders of the drive stem 202 are no longer adjacent the shoulders of the tool stem 203, as seen in
A third embodiment of the present disclosure is shown in
Unlike the previously described embodiments, as seen in
As seen in
As best seen in
In the embodiment shown in
The clamp connector 312 connects each of the plurality of locking clamps 306 to each other. The clamp connector 312 may include a groove for receiving an upper end of each locking clamp 316. The upper end of each locking clamp may be keyed to slide radially inward and outward within a corresponding groove of the clamp connector 312. As such, the clamp connector 312 may function as a guide as the locking clamps adjust radially from the open position (
As seen in
To release the preloading force clamping the drive and tool stems together, the actuator 310 may be actuated to move the sleeve 304 from the second or lower position to the first or upper position. Because of the upper and lower protrusions 326, 328 of each locking clamp 306 within the corresponding upper and lower slots of each retainer 329, the clamping members will move radially outward from the locked position towards the open position when the sleeve 304 moves from the second or lower position to the first or upper position.
In one or more of the embodiments described herein, a downhole tool coupling system includes a drive stem, a sleeve, and a plurality of locking clamps.
In one or more of the embodiments described herein, the sleeve is longitudinally movable relative to the drive stem.
In one or more of the embodiments described herein, the locking clamps are at least partially encompassed by the sleeve.
In one or more of the embodiments described herein, the locking clamps are rotatable between an open position and a locked position.
In one or more of the embodiments described herein, the sleeve is oriented relative to the locking clamps to rotate and radially move the locking clamps from the open position to the locked position as the sleeve moves longitudinally from a first position to a second position.
In one or more of the embodiments described herein, the locking clamps have an interior recessed region configured to clamp the drive stem to a tool stem when in the locked position.
In one or more of the embodiments described herein, the locking clamps are radially movable between an open position and a locked position.
In one or more of the embodiments described herein, the sleeve is oriented relative to the locking clamps to radially move the locking clamps from the open position to the locked position as the sleeve moves longitudinally from a first position to a second position.
In one or more of the embodiments described herein, the locking clamps are substantially similar in shape.
In one or more of the embodiments described herein, a bottom end of the drive stem comprises a plurality of shoulders configured to transfer torque to a tool stem.
In one or more of the embodiments described herein, the downhole tool includes an exterior housing.
In one or more of the embodiments described herein, the sleeve and the locking clamps are disposed within the exterior housing.
In one or more of the embodiments described herein, each locking clamp includes a lower exterior shoulder surface.
In one or more of the embodiments described herein, the sleeve is configured to engage the lower exterior shoulder surface and rotate and radially move each locking clamp from the open position to the locked position as the sleeve moves longitudinally from the upper position to the lower position.
In one or more of the embodiments described herein, each locking clamp includes an upper exterior shoulder surface.
In one or more of the embodiments described herein, the sleeve is configured to engage the upper exterior shoulder surface and rotate and radially move each locking clamp from the locked position to the open position as the sleeve moves longitudinally from the lower position to the upper position.
In one or more of the embodiments described herein, a top end of the sleeve has an inner diameter smaller than an inner diameter of a bottom end of the sleeve.
In one or more of the embodiments described herein, each locking clamp has an exterior surface located between the upper and lower exterior shoulder surfaces.
In one or more of the embodiments described herein, the exterior surface of each locking clamp has a generally convex shape.
In one or more of the embodiments described herein, the downhole tool includes an actuator configured to move the sleeve from the first position to the second position.
In one or more of the embodiments described herein, the sleeve the actuator and the locking clamps are disposed within the exterior housing.
In one or more of the embodiments described herein, the actuator has an upper stop and a lower stop and the exterior housing has a protrusion located between the upper and lower stops of the actuator.
In one or more of the embodiments described herein, the interior recessed recessed region of each locking clamp includes an upper edge and a lower edge.
In one or more of the embodiments described herein, the upper edge of each interior recessed region engages a ridge of the drive stem.
In one or more of the embodiments described herein, the interior recessed region of each locking clamp is configured to enable each locking clamp to rotate about the ridge of the drive stem when rotating and radially moving from the open position to the locked position.
In one or more of the embodiments described herein, the downhole tool includes a plurality of retainers attached to an internal surface of the sleeve.
In one or more of the embodiments described herein, each locking clamp includes a first protrusion extending from a first sidewall and a second protrusion extending from an opposing second sidewall.
In one or more of the embodiments described herein, each retainer is located between two of the plurality of locking clamps and includes at least one slot for receiving one of the protrusions of each of the adjacent locking clamps.
In one or more of the embodiments described herein, each locking clamp has a lower exterior shoulder.
In one or more of the embodiments described herein, the sleeve includes a lower protrusion configured to engage the lower exterior shoulder and radially move each locking clamp from the open position to the locked position as the sleeve moves longitudinally from the first position to the second position.
In one or more of the embodiments described herein, each locking clamp has clamp has an upper exterior shoulder.
In one or more of the embodiments described herein, the sleeve includes an upper protrusion configured to engage the upper exterior shoulder and radially move each locking clamp from the open position to the locked position as the sleeve moves longitudinally from the first position to the second position.
In one or more of the embodiments described herein, the lower exterior shoulder includes a first lower exterior shoulder surface and a second lower exterior shoulder surface.
In one or more of the embodiments described herein, the first and second lower exterior shoulder surfaces include a taper.
In one or more of the embodiments described herein, the taper of the first lower exterior shoulder surface is steeper than the taper of the second exterior shoulder surface.
In one or more of the embodiments described herein, the upper exterior shoulder includes a first upper exterior shoulder surface and a second upper exterior shoulder surface.
In one or more of the embodiments described herein, the first and second upper exterior shoulder surfaces include a taper.
In one or more of the embodiments described herein, the taper of the first upper exterior shoulder surface is steeper than the taper of the second upper exterior shoulder surface.
In one or more of the embodiments described herein, the lower protrusion of the sleeve has a surface profile mirroring a surface profile of the lower exterior shoulder and the upper protrusion of the sleeve has a surface profile mirroring a surface profile of the upper exterior shoulder.
In one or more of the embodiments described herein, the downhole tool includes an actuator adapter encompassing the drive stem.
In one or more of the embodiments described herein, the actuator adapter includes an upper stop and a lower stop.
In one or more of the embodiments described herein, an actuator has a protrusion located between the upper and lower stops of the actuator adapter.
In one or more of the embodiments described herein, a method for connecting a drive stem and a tool stem includes moving a sleeve longitudinally relative to the drive stem from a first position to a second position, moving a plurality of locking clamps radially between an open position and a locked position as the sleeve moves from the first position to the second position, the plurality of locking clamps at least partially encompassed by the sleeve, and engaging the tool stem with the plurality of locking clamps, thereby connecting the drive stem to the tool stem in the locked position.
In one or more of the embodiments described herein, a method for connecting a drive stem and a tool stem includes moving a sleeve longitudinally relative to the drive stem from a first position to a second position, rotating a plurality of locking clamps radially between an open position and a locked position as the sleeve moves from the first position to the second position, the plurality of locking clamps at least partially encompassed by the sleeve, and engaging the tool stem with the plurality of locking clamps, thereby connecting the drive stem to the tool stem in the locked position.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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