Patent Grant
10132118
Embodiments of the present invention 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 invention 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.
In an embodiment, a drive unit of a top drive system includes a first, second, and third drive gears, wherein the first, second, and third drive gears are operationally coupled; a motor engagable with the first drive gear; a drive stem having a load coupling and engagable with the second drive gear; and a torque shaft having a torque coupling and engagable with the third drive gear, wherein the drive stem cannot engage with the second drive gear when the torque shaft is engaged with the third drive gear, and vice versa.
In an embodiment, a method of coupling a drive unit to a tool adapter includes positioning the tool adapter below the drive unit; engaging a first drive gear with a motor of the drive unit while engaging a second drive gear with a drive stem of the drive unit; coupling a load between the drive stem and a tool stem of the tool adapter; and coupling a torque between a torque shaft of the drive unit and the tool stem.
In an embodiment, a top drive system includes a drive unit; a tool adapter having a tool stem; a first torque path including: a motor of the drive unit; a first pair of operationally coupled drive gears of the drive unit; a drive stem of the drive unit; a threaded connection between the drive stem and the tool stem; and a second torque path including: the motor; a second pair of operationally coupled drive gears of the drive unit; a torque shaft of the drive unit; and a torque coupling between the torque shaft and the tool stem.
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, 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 invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
The present invention provides equipment and methods for coupling a top drive to one or more tools. The coupling may transfer torque bi-directionally from the top drive to the one or more tools. The coupling may provide mechanical, electrical, optical, hydraulic, and/or pneumatic connections. The coupling 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 to support high axial loads, good sealability, resistance to bending, high flow rates, and high flow pressures.
Some of the many benefits provided by embodiments of this disclosure include a reliable method to transfer full bi-directional torque, thereby reducing the risk of accidental breakout of threaded connections along the tool string. Embodiments of this disclosure also provide a fast, hands-free method to connect and transfer power from the drive unit to the tool adapter. Embodiments provide automatic connection for power and data communications.
In some embodiments, the torque transfer path from the top drive system to the tool string bypasses the threaded connection between the drive unit and the tool adapter. This may allow full bi-directional torque to be applied in the tool string. This compares to systems wherein the torque transfer path proceeds through the threaded connections between the drive unit and the tool adapter which present a risk of backing out the main threaded connection while rotating in the breakout direction.
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Drive gears 130 may shift between a first position, wherein drive gears 130 engage—directly or indirectly—with drive stem 180, and a second position, wherein drive gears 130 engage—directly or indirectly—with torque shaft 190. For example, in the embodiment illustrated in
Drive unit 110 may be coupled to tool adapter 150 in order to transfer bi-directional torque, load, power, data, and/or signals between the top drive and the tool. Coupling of drive unit 110 to tool adapter 150 may proceed as a multi-step process. In one embodiment, as illustrated in
In some embodiments, coupling drive stem 180 to tool stem 160 may be facilitated with various sensors, actuators, couplers, and/or adapters. For example, tool stem 160 may be positioned for coupling and supported while coupling by a positioning adapter 261. The positioning adapter 261 may include a clamp 262 (e.g., an articulating claim), one or more actuators 263 (e.g., thread compensation cylinders), one or more supports 264 (e.g., a torque reaction post), and one or more hinges 266. The supports 264 and hinges 266 may fix positioning adapter 261 to housing 120. The actuators 263 may cause the hinges 266 and supports 264 to move clamp 262 into position to receive tool stem 160. In the embodiment illustrated in
Coupling of drive unit 110 to tool adapter 150 may proceed with bi-directional torque coupling between torque shaft 190 and tool stem 160, as illustrated in
In some embodiments, coupling torque shaft 190 to tool stem 160 may be facilitated with various sensors, actuators, couplers, and/or adapters. For example, torque shaft 190 may be first oriented relative to tool stem 160 so that key couplings 172 align. A sensor 291 (e.g., an optical sensor;
As another example, movement of torque shaft 190 between the raised position (
As another example, connection of additional coupling 170 between torque shaft 190 and tool stem 160 may be facilitated with various sensors, actuators, couplers, and/or adapters. Couplings 170 may include one or more hydraulic, pneumatic, electrical, or optical couplings, providing fluid, electrical, optical, signal, data, and/or power communication between the drive unit 110 and the tool adapter 150. For example, as illustrated in
As another example, the coupling of torque shaft 190 to tool stem 160 may be further facilitated with various sensors, actuators, couplers, and/or adapters. For example, the torque coupling may be facilitated with a locking adapter having related sensor(s) and actuator(s). Once torque shaft 190 has moved to the lowered position and coupled to tool stem 160, as shown in
It should be appreciated that other sensors, actuators, and/or adapters types and/or configurations may be considered to accommodate manufacturing and operational conditions. The actuators may be, for example, worm drives, hydraulic cylinders, compensation cylinders, etc. The actuators may be hydraulically, electrically, and/or manually controlled. In some embodiments, multiple control mechanism may be utilized to provide redundancy. One or more sensors may be used to monitor relative positions of the components of the top drive system 100. The sensors may be position sensors, rotation sensors, pressure sensors, optical sensors, magnetic sensors, etc. In some embodiments, stop surfaces may be used in conjunction with or in lieu of sensors to identify when components are appropriately positioned and or oriented (e.g., when drive gears 130 are in an upper position, when tool stem 160 is aligned with torque shaft 190, or when torque shaft 190 is in a lowered position). Likewise, optical guides may be utilized to identify or confirm when components are appropriately positioned and or oriented. In some embodiments, guide elements (e.g., pins and holes, chamfers, etc.) may assist in aligning and/or orienting the components of the top drive system 100. Bearings and seals may be disposed between components to provide support, cushioning, rotational freedom, and/or fluid management.
A method 300 of coupling drive unit 110 with tool adapter 150 is illustrated in
In an embodiment, a drive unit of a top drive system includes a first, second, and third drive gears, wherein the first, second, and third drive gears are operationally coupled; a motor engagable with the first drive gear; a drive stem having a load coupling and engagable with the second drive gear; and a torque shaft having a torque coupling and engagable with the third drive gear, wherein the drive stem cannot engage with the second drive gear when the torque shaft is engaged with the third drive gear, and vice versa.
In one or more embodiments disclosed herein, the first, second, and third drive gears are axially aligned on a common shaft.
In one or more embodiments disclosed herein, the load coupling is a threaded coupling.
In one or more embodiments disclosed herein, the torque coupling is a key coupling.
In one or more embodiments disclosed herein, the drive stem extends through a central bore of the torque shaft.
In one or more embodiments disclosed herein, the drive unit also includes a swivel co-axial with the torque shaft.
In one or more embodiments disclosed herein, the swivel is a hydraulic swivel.
In one or more embodiments disclosed herein, the drive unit also includes a shift actuator coupled to the first, second, and third drive gears, wherein the shift actuator is configured to move the first, second, and third drive gears between: an upper position wherein the second drive gear engages with the drive stem, and a lower position wherein the third drive gear engages with the torque shaft.
In one or more embodiments disclosed herein, the drive unit also includes a support actuator configured to move the torque shaft between: a raised position wherein the torque shaft is engaged with an alignment gear, and a lowered position wherein the torque shaft is disengaged with the alignment gear.
In one or more embodiments disclosed herein, the drive unit also includes a positioning adapter configured to move between a vertical position and a tilted position relative to the drive unit.
In one or more embodiments disclosed herein, the top drive system also includes a tool adapter having a complementary load coupling to the load coupling of the drive stem, and a complementary torque coupling to the torque coupling of the torque shaft.
In one or more embodiments disclosed herein, the drive unit further comprises a support actuator configured to move the torque shaft between: a raised position wherein the torque shaft is engaged with an alignment gear, and a lowered position wherein the torque shaft is coupled to the tool adapter.
In one or more embodiments disclosed herein, the drive unit further comprises a positioning adapter having a clamp; the tool adapter comprises a tool stem having a clamp profile; and the clamp is configured to engage the clamp profile to move the tool stem into position to couple with the drive stem.
In one or more embodiments disclosed herein, the top drive system also includes at least one coupling between the drive unit and the tool adapter selected from a group consisting of: threaded couplings, hydraulic couplings, pneumatic couplings, electronic couplings, fiber optic couplings, power couplings, data couplings, signal couplings, bi-directional torque couplings, axial load couplings, power couplings, data couplings, and signal couplings.
In an embodiment, a method of coupling a drive unit to a tool adapter includes positioning the tool adapter below the drive unit; engaging a first drive gear with a motor of the drive unit while engaging a second drive gear with a drive stem of the drive unit; coupling a load between the drive stem and a tool stem of the tool adapter; and coupling a torque between a torque shaft of the drive unit and the tool stem.
In one or more embodiments disclosed herein, the method also includes engaging the first drive gear with the motor while engaging a third drive gear with the torque shaft.
In one or more embodiments disclosed herein, the method also includes, after coupling the load between the drive stem and the tool stem, and before engaging the third drive gear with the torque shaft, disengaging the second drive gear with the drive stem.
In one or more embodiments disclosed herein, the disengaging the second drive gear with the drive stem follows the coupling the torque between the torque shaft of the drive unit and the tool stem.
In one or more embodiments disclosed herein, the method also includes moving the first and second drive gears from an upper position to a lower position to disengage the motor from the drive stem.
In one or more embodiments disclosed herein, the method also includes moving the torque shaft from a raised position to a lowered position to couple the torque.
In one or more embodiments disclosed herein, the method also includes moving a positioning adapter from a tilted position to a vertical position to position the tool adapter below the drive unit.
In one or more embodiments disclosed herein, coupling the load comprises rotating the drive stem relative to the tool stem in a first direction.
In one or more embodiments disclosed herein, the method also includes rotating the tool stem in the first direction.
In one or more embodiments disclosed herein, rotating the tool stem in the first direction comprises engaging the first drive gear with the motor while engaging a third drive gear with the torque shaft.
In one or more embodiments disclosed herein, coupling the torque comprises lowering the torque shaft relative to the tool stem.
In one or more embodiments disclosed herein, the method also includes aligning the torque shaft with the tool stem before lowering the torque shaft relative to the tool stem.
In one or more embodiments disclosed herein, the method also includes forming a coupling between the drive unit and the tool adapter, wherein the coupling is selected from a group consisting of: threaded couplings, hydraulic couplings, pneumatic couplings, electronic couplings, fiber optic couplings, power couplings, data couplings, signal couplings, bi-directional torque couplings, axial load couplings, power couplings, data couplings, and signal couplings.
In an embodiment, a top drive system includes a drive unit; a tool adapter having a tool stem; a first torque path including: a motor of the drive unit; a first pair of operationally coupled drive gears of the drive unit; a drive stem of the drive unit; a threaded connection between the drive stem and the tool stem; and a second torque path including: the motor; a second pair of operationally coupled drive gears of the drive unit; a torque shaft of the drive unit; and a torque coupling between the torque shaft and the tool stem.
In one or more embodiments disclosed herein, the second torque path bypasses the threaded connection between the drive stem and the tool stem.
In one or more embodiments disclosed herein, the first pair of drive gears and the second pair of drive gears share a common gear.
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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